How to Change Generator Rope With Recoil Spring | 6-Steps DIY Guide

Have you ever been in a situation where you needed your generator, but the pull rope refused to cooperate? The good news is that you can solve the problem on your own. You don’t need to be a mechanic or a DIY expert to make your generator pull cord work like new again.

But don’t worry, Generator Fixer is here to guide you through a six-step process to fix or change the pull cord on your Champion generator. The same process applies to other portable open-frame generators, such as Honda, Generac, Briggs & Stratton, Fairman, Screwfix, and DeWalt. If you’re ready to get your generator back to work, let’s get started.

How to Change Generator Rope (6-Easy) Steps

Tools and Materials Needed (List)

Safety first, before fixing a broken recoil rope, ensure the generator is turned off for at least 15 minutes and the spark plug wire boot is disconnected to prevent accidental auto starts. Wear safety goggles and work gloves to protect yourself from potential injuries.

Step 1: Access the Recoil Starter

The recoil starter is usually located on the side or top of the engine, near the air filter assembly, which is typically tucked away under a cover made of metal.

Step 2: Remove the Old Rope

Let’s get rid of that old rope on your generator. After finding the recoil starter cover, held on by three bolds.

Grab a T-handle socket measuring 10 or 8 millimeters, then twist those bolds to free the recoil starter cover.

Once the cover is removed, you’ll see the old rope wound around the recoil starter pulley.

Use a nose plier to yank that old rope out of there and toss it away.

Step 3: Select the New Rope

Now that you’ve successfully removed the old pull rope, it’s time to choose the right replacement cord.

The selection process is crucial to ensuring that the new rope is the correct size, diameter, and material for your generator. Here’s how to make the right choice:

Correct Size

Generator pull cord size is important measure the length of the old pull cord you just removed. It’s essential to match the new rope length as closely as possible to confirm it fits your generator correctly.

If you don’t have the old cord for reference, my recommendation is that the 2.5-fit size is commonly good. Otherwise, consult your generator owner’s manual for the recommended length.

Check the Diameter

Examine the diameter of the old cord and select a replacement rope with a similar diameter. Using a rope that’s too thick or too thin can affect how it fits and functions within the pull cord assembly.

Right Material

Replacement pull ropes are typically made from materials like nylon, polyester, or other durable fibers.

Confirm that the material you choose is suitable for the environmental conditions your generator may encounter.

For example, if your generator is often exposed to the elements, opt for a weather-resistant material.

Step 4: Install the New Rope

This time, thread that new rope through the starter assembly. Find the hole where the old rope used to hang out and push the new one through it.

If there are other holes it needs to go through, don’t forget them either. While you’re at it, keep some tension on the rope to avoid any messy tangles or twists.

Once the rope has navigated all the necessary guide holes, tie a knot on the other end. Make sure it’s big enough to stop the rope from slipping back through the assembly hole.

However, if you find that the recoil starter hole is getting worse and the rope is breaking frequently, then you need to change the whole recoil starter assembly.

Step 5: Adjust the Tension (it’s Important)

Tightening Tension: If the cord is too loose, wind it slightly tighter around the recoil starter pulley by turning the pulley clockwise. Be careful not to over-tight the cord.

Loosening Tension: If the rope is too tight, carefully unwind it from the starter pulley by turning the pulley counterclockwise (opposite direction of starting).

Remove any excess wraps until the tension is correct. Be cautious not to completely unwind the cord from the pulley. After making adjustments, ensure the pull rope has the right tension enough to retract the pulley smoothly but not overly tight.

Step 6: Putting the Cover Back

With the new rope perfectly in place and the rope tension adjusted, it’s time to reassemble the starter assembly cover. Carefully place the recoil starter cover back over the assembly, making sure it lines up with the holes in the generator housing.

Secure the cover in place by tightening the three (3) bolts you removed earlier using a T-handle socket wrench. And that’s it. You’re done. Your generator has a brand-new rope, and it is ready to power up when you need it.

How to Fix Generator Starter Spring?

Fixing or changing a recoil starter spring can involve a few steps. if needed otherwise, skip this section. But the above mentation process is the same.

Inspect Starter Spring: Check the starter spring for any signs of damage or wear. If the spring is broken or damaged, it will likely need to be replaced. If it’s just come loose, you may be able to reattach it.

Remove Old Spring:  Open one bolt located at the center of the recoil pulley using a T-handle socket. If the old starter spring is still attached to the pully, use pliers to carefully disconnect it from the starter mechanism. Take note of how the spring is positioned before removal.

Install New Spring: Take the replacement starter spring and position it in the same way as the old one. Make sure it is securely attached to the appropriate points on the starter mechanism. then reattach the recoil pully and bolt removed earlier.

Some springs may have specific hooks or anchor points, so refer to your generator’s manual if needed. Make sure the new spring is the correct size and type for your generator model.

If you have any difficulty understanding the starter spring changing the whole process, please watch this video.

Finally, reconnect the spark plug wire boot to the plug to start the generator and ensure that the new rope and starter spring engages smoothly and the starter functions correctly. If there are any issues, recheck your work and make adjustments as needed.

Why Generator Pull Cords Often Need Repair

Generator pull rope repair may be necessary for multiple reasons, including wear and tear, accidents, or mechanical issues that can affect the cord’s functionality

Common Reasons for Pull Cord Repair

According to my experience with regular customers who have generator issues.

Friction and Wear: Over time, the repeated pulling of the rope can cause it to fray, weaken and break. This is a common reason for a broken rope, especially with regular use.

Wrong Pulling Technique: Sometimes, users may pull the cord too forcefully or at an awkward angle, leading to kinks or knots in the cord. These can cause it to jam or break.

Wrong Rope Length: If the pull cord is too short or too long for the generator specifications or above the recommendation, it can affect its functionality and may need to be adjusted or replaced.

Corrosion and Rust: Exposure to moisture or humid conditions can lead to corrosion and rust on the components of the pull cord system, affecting its smooth operation.

Stuck or Jammed Cord: Dust, dirt, or debris can build up in the cord housing or on the recoil spring, leading the cord to become stuck or jammed when pulled.

Mechanical Issues: Problems with the generator recoil starter mechanism, such as a damaged spring or ratchet, can prevent the rope from pulling back properly or engaging the engine.

Old Components: As generators age, their pull cord assembly may fall apart, and require the change of various parts like the handle, cord, or recoil spring.

User Error: Incorrectly putting back together the pull cord recoil starter after maintenance or repair work can lead to issues with its operation.

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