Small Engines (Lawn Mowers, etc.): Toro ccr 2450, r tek, proper tension

Question
Model # 38515
R-TEK engine

My question is... The pull cord is not working properly.  I can tell it is still connected but it will only pull out a little at a time and only if you are very gentle with it.

Any advice on what I might be able to do with it?

Answer
Honeybunny
This sounds like the starter pawls may be broken or damaged. You will need to remove the pull starter cover and inspect the starter. Do not try to remove the spring as it will unwind  and possibly hurt some one.
Broken starter ropes or failure to retract are both repairs that are fairly easy. However, the spring can be nasty as it is under tension (or should be when reassembled). This can be risky if you are not familiar with the internal construction as you disassemble the unit.
The cause of a broken cord is obvious. The cause for a failure to retract could be a broken spring, tangled or frayed rope, or some other mechanical failure. A broken spring will require total disassembly of the starter mechanism - fortunately there really isn't that much involved.

With some designs, it is possible to replace the cord without fully disassembling the starter mechanism - by threading the cord in and tying a not in the end - but after rotating it several turns to put the proper tension on the spring. This is relatively safe but may be frustrating as 3 hands are sometimes needed.

Where safe disassembly is not obvious, I would recommend that you refer to a book on lawn mower or small engine repair from the library or the service manual for the mower, if possible. You may be able to find specific step-by-step instructions which will minimize your risk of injury from an encounter with an uncontrolled spring.


When the rope pulls out and retracts normally - but doesn't do anything else - the most likely cause is a problem with the one-way clutch. This may be part of the spring-rope assembly - usually removable as a unit - or attached to the flywheel. The most common problems are gummed up lubrication or a broken spring or other damaged or worn parts. For common engines:

WARNING: Take extreme care should you need to disassemble the portion of the starter that includes the mainspring - that can be nasty.