How to Change the Pull Cord on a Chainsaw

One of the things you’ll want to check on your chainsaw as you prep it for spring and summer use is the pull cord. The cord should be in decent shape, should be easy to pull, and shouldn’t have slack or snag on anything when used. If you’re running into any of these problems, it’s time to give your chainsaw a once over and possibly change the cord out.

Need some help with that? AppliancePartsPros.com has you covered! Let’s take a look at how to check, fix, or replace your chainsaw’s pull cord.

Why Is My Chainsaw Hard To Pull?

If the chainsaw’s cord is hard to pull, there are actually a few different things that could be causing trouble:

• The pull cord is twisted. By far the easiest thing to deal with is a twisted pull cord. Check your cord, and if it’s twisted up but everything else looks fine, just straighten it out.
  

• The cord or pulley is gunked up. Chainsaw cords can get coated in sap, matted with grass or straw, or covered in dirt and sawdust. Any excessive debris build up like this won’t just make your chainsaw’s pull cord difficult to use, it could possibly cause greater problems in the internal machinery. Try to clean the cord and recoil starter assembly as best you can, and don’t hesitate to replace it if clearing it off seems like an impossible task.

• The pull cord isn’t the right diameter. If your pull cord is too thick, it can get stuck in the pulley. If it’s too small, it can tangle up on itself. Make sure you’re using a cord of the appropriate thickness.

• The cord is fraying. Fraying cord can catch on itself, the pulley, or the starter housing, making it difficult to pull or stopping it from retracting once released. A frayed cord is one step away from snapping, so you should replace the cord if you notice this type of damage.
• Some part of the pulley system or starter assembly is damaged. Pulleys and bearings can wear out, springs can stretch and lose tension, housing components can break and get in the way. If any of these components are damaged, a pull cord in otherwise good condition may fail to function properly.

When Should I Replace A Chainsaw Pull Cord?

Most chainsaw cords are little more than rope, and the motion of the starting cord being pulled against pulleys and the chainsaw housing is eventually going to wear it out. If you use your chainsaw a lot, you’ll likely have to replace the pull cord eventually.

Obviously, if the cord has snapped, you’ll want to swap it out, but you should check the pull cord as part of normal maintenance. Replace it if you notice any of the following issues:

• A damaged cord handle
• Thinning or fraying of the cord
• Incorrect cord length or diameter
• Excessive build up of sap or other dirt that is difficult or impossible to clean

Finding The Right Replacement Chainsaw Pull Cord Part

Most pull cords are a standard 36” to 40” (or 1m) length of nylon or synthetic rope, but the thickness of the rope can vary. Get a rope that’s too wide or too thin and you may have too much or too little cord to go around the pulley the appropriate number of times, which will cause issues with pull-starting your chainsaw.

Make sure you select the right diameter for your pull cord when buying a replacement! Most chainsaws use #4 cord.

Your best bet is to opt for a genuine OEM replacement pull cord for your chainsaw. That way, you’re guaranteed to get the exact length and width you need for your chainsaw. To find an exact OEM replacement, you’ll need your chainsaw’s model number, which you’ll be able to find somewhere on the equipment – likely the bar. Once you have that, you can search for a replacement pull cord online. At AppliancePartsPros.com, we’ve got plenty of OEM chainsaw parts for a variety of brands.

How To Change The Pull Cord On A Chainsaw

As most pull cords are changed out in roughly the same way, we’ve provided a general overview of how to replace a cord here. The instructions we’ve laid out should apply to most chainsaws regardless of brand or model, but you may want to consult your product manual for additional, more specific instructions, as well.

Tools for the job

You don’t need much to switch out your chainsaw’s pull cord, and you may not need every item listed here. However, it’s a good idea to have these items ready before you begin:

• A replacement pull cord
• A lighter
• A box cutter
• A pair of needle nose pliers
• An appropriately sized socket and wrench, torx screwdriver, or drill; check your chainsaw and consult your manual to see which size tool you will need to disassemble the starter cover
• Work gloves

Replacing A Chainsaw Pull Cord

1. Start by safely preparing your chainsaw for maintenance. Make sure it’s powered off and completely cool before you begin, and set it on a sturdy work surface. Pull the spark plug wire off the plug and make sure it’s out of the way to avoid any accidental ignition.
2. Remove the recoil housing. It will be held in place, usually, by three or four screws or bolts. You can use a torx screwdriver, socket, or drill to remove these.
3. Check the starting assembly. Turn the recoil housing cover over. You can find the pulley and cord here. Check the pulley for any signs of damage, as it is not unusual for this part to need replacing along with the pull cord.
4. Cut the knots off the old pull cord. If the pull cord is already snapped, you won’t need to do this, but the easiest way to remove the cord both from the handle and the pulley is by cutting the knots and pulling the cord out. Use a pair of needle nose pliers to pull the knot on top of the pulley out for cutting, then slacken the rope on the handle to cut that knot as well.
5. Clean up the recoil starter assembly if necessary. If your starter assembly is extremely gunked up, now would be a good time to clean it. You can use a soft brush and an air canister to brush it away.
6. Cut your starter rope to length. 36 to 40 inches is standard. If you are using a synthetic fiber rope (you probably are), you can use a lighter to melt each end and roll them to eliminate frayed ends.
7. Thread the other end of the cord through the opening in the top of the starter pulley. You can use a pair of needle-nose pliers to pull it through once it’s threaded. Leave yourself enough slack to tie a tight knot at the end of the rope that’s on top of the pulley, then tuck the knotted cord into place.
8. Feed the loose end of the cord through the hole in the starter housing.
9. Insert the cord into the handle, then knot it at the top. Make sure the knot is tight, as this will secure it.
10. Hold the cord straight with your thumb and wind the pulley clockwise. Make note of how many full turns you do.
    1. How many turns you will need to do total will depend on your chainsaw. Starting out with 3 – 4 full turns is enough.
    2. Once you’ve done 3 – 4 full turns, slowly let the pulley unwind while you guide the cord into the pulley’s groove. The cord will wrap around the pulley.
    3. If you still have slack after 3 or 4 turns, repeat the process, working in 1 – 2 turn increments until the handle contacts the starter housing.
11. Give the assembly a test pull. There should be a bit of tension on the pulley, and when you release the rope after pulling it, it should immediately slide all the way back into place.
12. Time to reassemble! Reinstall the starter assembly cover and then reattach the spark plug wire. With everything put back together, you can give the chainsaw a real test start up.

Wrapping Up

By following this guide, you should have successfully replaced the pull cord on your chainsaw – making your life a lot easier and better protecting the interior components of your equipment from damage. Got other work you need to do in your home or garden? Check out how else AppliancePartsPros.com can help. We’ve got tips, tutorials, and genuine OEM replacement parts for all your appliance and lawn equipment needs.