Testing and replacing a chainsaw starter assembly

Is your chainsaw giving you the silent treatment when you yank that starter cord? Maybe the starter assembly’s acting up. When the recoil spring or the cord is shot, your chainsaw won’t fire up. In this guide, we’ll show you how to check and swap out a chainsaw starter assembly, so you can get your trusty tool back in action and save some cash along the way.

The info here might not match your exact chainsaw model. We do our best to give helpful tips for all sorts of DIY fixes, but different models can have variations in troubleshooting steps, parts, and so on. For the most accurate advice, it’s best to check your chainsaw’s manual or get in touch with us if you’ve got questions.

Understand your chainsaw’s starter assembly

When you pull the starter cord on your chainsaw, the recoil mechanism kicks in and spins the engine’s crankshaft. This movement sucks fuel and air into the combustion chamber, letting the ignition system spark up the fuel-air mix to get your chainsaw running. The starter assembly is made up of a rope, a pulley, and a recoil spring that pulls the rope back into place for the next pull. If any part of this setup is bad, your chainsaw might refuse to start. 

Common signs of starter assembly problems

Before we dive into taking things apart, it’s good to spot the signs of starter assembly trouble. If you notice any of these issues, it’s time to take a closer peek. Testing thoroughly helps you zero in on the problem before wasting time or cash on parts you don’t need. You might run into:

• The starter rope feels stuck and won’t pull out.
• The rope pulls out but doesn’t retract properly, or not at all.
• You hear grinding or squealing sounds when you pull the rope.
• No resistance in the rope when pulling, which might mean a loose recoil spring.

Safety tips

Chainsaws are no joke—they move fast, and even when you’re just fixing the starter assembly, safety’s gotta be your top priority. Here are some precautions we’d suggest:

• If working indoors, make sure there is adequate ventilation to prevent the buildup of exhaust fumes. Carbon monoxide poisoning can be a serious risk.
• Wear insulated work gloves to protect your hands from sharp metal parts, pinching hazards and debris.
• Never attempt to service or repair while it is running or when the engine is still warm. Wait for all moving parts to come to a complete stop.
• Exercise extreme caution when working near blades, augers, or any other moving parts. Keep your hands, fingers, and clothing clear of these areas at all times.
• If the appliance has recently been used, give it plenty of time for any hot parts to cool down before working on it. 
• Empty the gas tank before beginning any work. Refill using fresh fuel. 
• Clean up oil spills right away to prevent slipping or other damage. 
• When working with wires, avoid touching any exposed wires or terminals. If you need to touch a wire, use a non-conductive tool or wear insulating gloves to prevent electrical shock.
• Take your time and don’t rush while working to prevent accidents and personal injuries.
• Work in a well-lit area so you can clearly see and access the interior parts.
• Clear your workspace of clutter and other obstacles. Keep children and pets away from the work area.
• Be gentle when handling or removing parts. Excessive force might damage the appliance or cause injury.
• Wear safety glasses when working with chemicals, dust or cleaning large debris to prevent injury. 
• When not in use, store the machine in a safe and dry location.

Remove the starter assembly

First up, you need to get the starter housing off your chainsaw. Different models might vary a bit, but usually, you can follow these steps:

1. Find the screws or bolts keeping the starter cover in place.
2. Grab the right screwdriver or wrench to take them out. Put the screws somewhere safe so you don’t lose ’em.
3. Carefully lift off the cover to see the starter bits: the rope, pulley, and recoil spring setup.

Diagnose the recoil spring and cord

Now that you’ve got access to the starter rope and recoil spring, it’s time to check ’em out. The rope usually winds around a pulley, and the recoil spring sits underneath or inside that setup. Common issues are a frayed rope or a tangled or busted recoil spring. Here’s what to look for:

1. Check the rope for any visible damage. If it’s frayed or missing chunks, it’s time to replace it.
2. Take a look at the recoil spring. Sometimes, it loses tension or snaps altogether. If it’s not coiled right or looks bent or broken, you might need a new spring.
3. Inspect the pulley for cracks or deformations that could stop the rope or spring from moving freely.
4. If the rope looks fine but the spring is jammed, you’ve probably got a recoil spring issue. If the rope’s clearly frayed or snapped, then you need a new starter cord.

Test the recoil spring tension

The recoil spring’s job is to pull the starter rope back onto the pulley after each yank. If the tension’s weak or the spring’s busted, the rope will hang loose instead of snapping back. Here’s a simple way to test the recoil spring tension:

1. Grab the rope and pull it out an inch or two.
2. Let go and watch how it retracts. It should pull back smoothly and stay tight.
3. If there’s little to no resistance, or the rope doesn’t recoil, you’ve either got a damaged spring or it’s not seated properly on the pulley.
4. Carefully remove the pulley to check the spring underneath. Pay attention to how the spring is positioned so you can put it back right. 
5. Sometimes, just re-seating the recoil spring can fix the issue if it was out of place. But if you see any wear and tear, breakage, or a warped spring, it’s best to swap it out for a new one.

Replace the starter cord

If your starter cord’s frayed or snapped, swapping it out is a quick fix to get your chainsaw’s starter working again. First, grab the right size rope for your model. Both thickness and length matter. If you’re not sure, check the manufacturer’s guidelines:

1. Cut a new piece of rope that matches or is slightly longer than the original. You can always trim it down later.
2. Thread one end of the rope through the handle. Tie a solid knot to secure it, making sure it sits snug in the handle’s recess.
3. Wind the other end of the rope around the starter pulley. Make sure to feed it through any holes or guides meant to keep it in place.
4. If your pulley has a channel or hole where the rope’s end needs to be secured, line it up right and tie a knot that fits snugly.
5. After you’ve attached the rope to the pulley, gently pull it to make sure it’s seated properly. If it moves freely, you’re good to go. If it jams or doesn’t hold tension, you might need to take it off and try again. 
6. Once you’re sure the rope moves smoothly, wind up the recoil spring so there’s enough tension to retract the rope properly. Usually, this means winding the pulley a certain number of turns (as per the manufacturer’s instructions) to preload the spring.

Reassemble and perform final check

Putting it all back together is just as important as taking it apart, even if people often skip over it in tutorials. After you’ve fixed or replaced the cord and recoil spring, follow these steps:

1. Align the starter pulley and housing, making sure the rope is threaded through the right opening on the chainsaw cover.
2. Put the starter cover back on the chainsaw. Tighten the screws or bolts you took out earlier—don’t overtighten them.
3. Double-check that the rope handle is outside the cover and moves freely. A quick pull test here is key to see if everything lines up right.
4. If you removed the spark plug wire, reconnect it and make sure the chainsaw’s ready for a test run.

Additional information

Thanks for reading! If you still need replacement parts, grab your model number and head to AppliancePartsPros.com. We offer over two million parts and most orders arrive in two business days. If you need help finding the right part or placing an order, you can contact our team at 1 (877) 477-7278.

While you’re waiting for your new part to arrive, you can explore our DIY blog and watch thousands of video tutorials on our YouTube channel.

Be sure to follow us on Facebook, Twitter and Instagram to see our latest repair guides!