To fix a pull start that won’t retract, clean the housing, re-tension the recoil spring 4–6 turns, replace frayed rope, and lube pivots lightly.
A stuck recoil is annoying, but it’s fixable with basic tools and a calm, methodical approach. This guide shows how to diagnose the starter, reset spring tension, replace a worn rope, and put everything back together without drama. You’ll also learn where light lube helps and where it hurts.
These steps apply to most small engines on mowers, generators, trimmers, pressure washers, and compact tillers. Designs vary, so check model-specific instructions when you reach a detail that looks different on your machine.
Safety First And Tools You’ll Need
Kill the engine, pull the spark-plug boot, and let the machine cool. Wear gloves and eye protection. The recoil spring stores energy; handle the pulley with care so it doesn’t whip.
Basic Tool List
- Screwdrivers, nut driver, or socket set
- Torx or Allen bits where required
- Needle-nose pliers and side cutters
- A short length of starter rope and a lighter to melt the tip
- Dry PTFE spray and a drop of light oil
Fixing A Pull Start That Won’t Retract: Quick Causes
Before tearing it apart, match the symptom to a likely cause. Use this table as a fast map, then follow the detailed steps below.
| Symptom | Likely Cause | Fast Fix |
|---|---|---|
| Cord stays out | Low spring tension or broken spring | Pre-wind pulley; replace spring if it won’t hold |
| Slow return | Dirty pulley, sticky pawls, rope drag | Clean housing; dry-lube pivots; check rope path |
| Sharp snap back | Over-tensioned spring | Back off one turn on the pre-wind |
| Won’t pull at all | Pawl jam or crank jam | Open housing; free pawls; check flywheel area |
| Frayed rope | Worn eyelet or off-angle exit | Replace rope; smooth the eyelet path |
| No engagement | Pawls stuck or worn dogs on the cup | Clean or replace pawls; inspect starter cup |
| Grinding feel | Cracked pulley or missing bushing | Replace damaged parts |
Step-By-Step: Reset Tension And Restore Return
1) Remove The Starter Housing
Disconnect the spark plug. Remove the screws around the shroud and lift the starter housing straight off. Note any washers or spacers. Keep parts in order so reassembly goes smoothly.
2) Inspect And Clean
Brush away grass, dust, and rope fibers. Check the pulley rim, center bushing, pawls, and the starter cup on the flywheel. If the cup is burred or cracked, plan on a replacement. Clean with a dry brush and compressed air; avoid heavy grease inside the housing.
3) Check The Rope Path
Make sure the rope runs through the guide and exit eyelet without rubbing sharp edges. If the eyelet lip is rough, smooth it with fine paper. Replace the rope if it shows glazing, flattening, or broken fibers.
4) Pre-Wind The Spring
Hold the pulley and turn it in the winding direction to load the recoil spring. Count four to six full turns on most units. Align the rope hole, then pin the pulley in place with a screwdriver through the housing to hold tension.
5) Feed And Tie The Rope
Melt the tip, thread the rope through the pulley and exit eyelet, and tie a secure stopper knot. Fit the handle and test the travel. The handle should sit against the housing with a small amount of reserve cord left on the pulley.
6) Fine-Tune Tension
If the cord hangs loose, add one pre-wind turn. If it slams back or the handle home position is too tight, remove a turn. Aim for a smooth pull and a brisk return that stops without a slap.
7) Free And Lube Pawls
Starter pawls should pivot out cleanly and retract under their springs. Flush grit, then apply a tiny shot of dry PTFE on the pivots and the pulley hub. Skip sticky oil on the pawls; it collects dust and slows them down.
8) Refit The Housing
Set the housing back over the cup, line up the dowels, and tighten the fasteners evenly. Pull the cord a few times to confirm the pawls engage and the rope returns cleanly.
When You Need A New Rope Or Spring
If the rope is sun-bleached, stiff, or flat from years of use, replace it now. Starter rope is inexpensive and saves repeat work. A broken or weak spring shows up as zero return, or a return that fades during the day.
Choosing Rope Size
Most walk-behind mowers use rope in the 3 to 4 mm range; generators and larger engines often use heavier line. Match the diameter and length to your model to avoid drag or short travel.
Spring Swap Basics
If the spring has cracked or lost strength, replace it as a unit when possible. Many pulleys include the spring pre-wound in a service assembly, which makes the job faster and safer. If you must handle a bare spring, wear eye protection and keep the coils caged while you guide them back into the hub.
Model-Specific Notes And Manuals
Exact steps and part sizes vary by brand. For specs, routing diagrams, and torque notes, check the official manuals. Start with the Briggs & Stratton manuals and the Honda Engines manuals. These pages list rope diameters, pulley assemblies, and service kits for common models.
Deeper Troubleshooting If It Still Won’t Retract
Pawl Issues
Pawls that stick half-open won’t clear the cup during return, which drags the pulley. Clean the pivots and check the tiny springs. Replace worn pawls and any cupped or swollen plastic parts.
Pulley Damage
Look for cracks at the hub and chips on the rope groove. A pulley that wobbles on the post or scrapes the housing will never return cleanly. Replace the pulley or the bushing if there’s play.
Starter Cup Wear
If the cup ears are rounded, the pawls won’t catch solidly and may hang up. Swap the cup and recheck alignment. Clean rust off the cup with a Scotch-Brite pad so the pawls slide freely.
Shroud Misalignment
After prior repairs, the shroud can sit off-center and bind the pulley. Loosen the fasteners, nudge the housing until the rope path sits square, and tighten again in a cross pattern.
Engine-Side Causes
If the engine is locked by a hydro-locked cylinder or a seized accessory, the rope may hang or jump. Pull the spark plug and try spinning the flywheel by hand. If the flywheel won’t move, address the engine issue first.
Starter Rope Sizes And Lengths By Tool Type
Use these ranges as a planning guide. Always check your manual before ordering parts.
| Equipment | Typical Diameter | Typical Length |
|---|---|---|
| Walk-behind mower | 3.0–3.5 mm | 80–110 cm |
| Generator (2–7 kW) | 3.5–4.0 mm | 100–130 cm |
| Chainsaw/leaf blower | 2.5–3.0 mm | 70–100 cm |
| Pressure washer | 3.5–4.0 mm | 100–130 cm |
| Tiller/plate compactor | 3.5–4.5 mm | 100–140 cm |
Simple Habits That Prevent A Stuck Recoil
Keep The Path Clean
After dusty jobs, pop the shroud and blow out debris from the pulley, pawls, and rope exit. Grit acts like sandpaper on the rope and slows the return.
Lube With Restraint
One small drop of light oil on the center post is plenty. For pivots and slides, use a dry PTFE spray. Avoid heavy grease on the spring and keep oil off the rope.
Protect The Rope
Store the machine out of sun and fuel vapors. UV and fumes harden nylon fibers, which leads to frays and short cords. Replace rope at the first sign of flattening.
Use A Smooth Pull
Let the pawls engage, then pull in one steady motion. Guide the handle back in rather than letting it snap. That habit preserves the spring and the handle mount.
When To Replace The Whole Assembly
Starter housings are affordable on many models. If the hub is worn, the pulley chews through posts, or the spring keeps slipping its catch, a complete assembly can save time. Match the part number from your model tag so the mounting holes and cup depth line up.
Common Replace-As-A-Unit Clues
- Broken spring with damaged tabs in the hub
- Egg-shaped center post or seized bushing
- Pawl mounts cracked or missing
- Shroud warped from heat or impact
Quick Reference Checklist
- Kill ignition and pull the plug wire
- Remove the housing and clean everything
- Inspect rope, eyelet, pulley, pawls, and the cup
- Pre-wind 4–6 turns, then feed and tie the rope
- Set tension so return is crisp, not violent
- Dry-lube pivots; one drop of oil on the post
- Reinstall shroud, test engagement and return
Do those steps and a pull start that won’t retract turns into a quick, satisfying fix.