My Petrol Strimmer/Brush Cutter pull cord is faulty

Quick Answer

If the pull cord on your petrol strimmer or brush cutter is stuck, will not retract, feels loose, or will not pull out, the starter assembly is likely to be faulty and may need replacing. If only the pull handle is damaged, you may only need to replace the starter grip.

⚠️ Safety Notice

Before carrying out any maintenance:

• Switch off the engine and allow it to cool completely.
• Remove the spark plug cap to prevent accidental starting.
• Wear suitable protective gloves.
• This repair involves removing the clutch assembly and should only be carried out by someone with suitable mechanical knowledge and the correct tools.

Incorrect reassembly may result in damage to the machine or prevent drive from being transmitted to the cutting attachment.

Common Pull Cord Faults

You may need to replace the starter assembly if the pull cord:

• Will not pull out properly
• Is stuck
• Feels loose
• Does not retract correctly
• Snaps during use

Replacing the starter assembly is a complex repair because it requires removal of the clutch assembly using specialist tools.

If you are not confident carrying out this repair, we recommend contacting our Warranty & Technical Support Team to discuss repair options. Alternatively, a qualified mechanic or technician can carry out the repair.

Replacement starter assemblies are available through our website or via our Spares Helpline.

Damaged Pull Handle Only

If only the plastic pull handle has broken and:

• The starter cord is still intact
• The cord retracts correctly

you may only need to replace the starter grip, rather than the complete starter assembly.

Replacement starter grips are available through our website or via our Spares Helpline.

Replacing the Starter Assembly

⚠️ Warning: This procedure is complex and requires specialist tools and mechanical experience.

Tools Required

• Torx bit (T25/T27)
• Piston stop
• Precision pliers
• Clutch removal tool

Parts Required

• Replacement starter assembly

Removal Procedure

Step 1 – Remove the Starter Housing

1. Using a T25/T27 Torx bit, remove the four screws securing the cone to the starter assembly.
2. Carefully separate the cone from the starter assembly.

Step 2 – Lock the Engine

1. Remove the spark plug.
2. Install a piston stop to prevent the engine from turning.

Step 3 – Remove the Clutch

1. Remove the retaining bolt from the centre of the clutch housing.
2. Remove the retaining circlip from the top of the clutch.
3. Using a clutch removal tool, rotate the clutch anti-clockwise.
4. Remove the clutch and the backing plate.

Step 4 – Remove the Starter Assembly

1. Remove the four screws securing the starter assembly.
2. Remove the two screws securing the rear engine cover (black plastic cover).
3. Unclip the retaining clip joining the two covers on the right-hand side.
4. Remove the starter assembly.

Step 5 – Install the Replacement

Fit the new starter assembly into position.

Reassembly

Reassemble the machine by reversing the removal procedure.

During reassembly ensure:

• The clutch is tightened correctly.
• The retaining circlip is securely refitted.
• The upper shaft is correctly aligned with the clutch housing.
• The main drive shaft engages fully with the drive slot.

⚠️ Important: If the drive shaft is not correctly engaged, the engine will run normally but the strimmer head or brush cutter blade will not rotate.

If You Are Unsure

If you do not have the required tools or mechanical experience, do not attempt this repair.

Please contact our Warranty & Technical Support Team for advice on repair options or replacement parts.

Frequently Asked Questions

Why won't my pull cord retract?

A pull cord that will not retract is usually caused by a faulty starter assembly or damaged recoil spring.

Can I replace just the pull handle?

Yes. If only the plastic handle is damaged and the cord still retracts normally, you only need to replace the starter grip.

Why is replacing the starter assembly difficult?

The repair requires removal of the clutch assembly using specialist tools and correct reassembly of the drive components.

What happens if the drive shaft is not fitted correctly?

The engine may start and run normally, but no drive will be transmitted to the strimmer head or brush cutter blade.