A broken pull cord on your John Deere JS60 lawnmower can bring your yard work to a frustrating halt. There’s nothing quite like tugging only to feel a limp rope, signaling that the vital connection to your engine has snapped. While this might seem like a daunting repair, replacing the pull cord for your JS60’s recoil starter assembly is a surprisingly straightforward task that most homeowners can accomplish with basic tools and a bit of patience. This article will guide you through each step of the process, from gathering the necessary parts and tools to safely reassembling your mower, ensuring you can get back to maintaining your lawn without the expense of a professional repair. We’ll cover everything you need to know to breathe new life into your John Deere JS60.
Gathering your tools and materials
Before you begin any repair, especially one involving a spring-loaded mechanism like a recoil starter, it’s crucial to gather all your tools and replacement parts. Having everything ready not only speeds up the process but also minimizes frustration and ensures you don’t have to stop mid-task. For this project, you’ll need a new recoil starter rope, sometimes referred to as a pull cord. Ensure it’s the correct diameter and length for a John Deere JS60; typically, a 5/32-inch diameter rope, about 80-100 inches long, is suitable, though checking your mower’s manual for exact specifications is always best. You’ll also need a pair of sturdy work gloves to protect your hands, especially when handling the spring. A Torx bit set or an appropriately sized socket wrench will be required to remove the bolts securing the recoil starter housing. Pliers, a utility knife or sharp scissors for cutting and trimming the rope, and a lighter or matches to singe the ends of the new rope are also essential. Finally, a small flathead screwdriver can be invaluable for prying or carefully manipulating parts, and a clean cloth will be useful for wiping away any grime.
Safely accessing the recoil starter assembly
Safety is paramount when working on any machinery. Always start by disconnecting the spark plug wire from the spark plug. This prevents the engine from accidentally starting while you’re working, eliminating the risk of injury. Locate the recoil starter assembly, which is usually positioned on top or side of the engine, often covered by a shroud. On the John Deere JS60, it’s typically a black or green plastic housing with the pull handle extending from it. You’ll notice several bolts securing this assembly to the engine. Using your Torx bits or socket wrench, carefully loosen and remove these bolts. Keep track of them; sometimes, they vary in length or type. Once all the securing bolts are removed, gently lift the entire recoil starter assembly off the engine. Take care not to force it, as there might be a small amount of resistance if it’s been in place for a long time. Once separated, place the assembly on a clean, stable workbench. This exposed unit is what we’ll be working on to replace the pull cord. Before proceeding, give the area a quick wipe down with your clean cloth to remove any accumulated grass clippings or dirt, which can make the job cleaner and prevent debris from entering the engine area.
Replacing the pull cord and recoil spring considerations
Now that the recoil starter assembly is off, you can begin the actual cord replacement. If the old cord is still present but broken, pull out any remaining fragments from the handle and the starter pulley. If the cord is completely gone, identify the small hole in the starter pulley where the cord feeds through. Before feeding the new cord, it’s crucial to address the recoil spring. This spring provides the tension that retracts the rope. If your old cord snapped because the spring lost tension, you might need to re-tension it. To do this, wrap the new cord around the pulley a few times (usually 2-3 times in the direction it normally winds) and then feed it through the hole. Tie a sturdy stopper knot at the end that goes inside the pulley. A figure-eight knot or a double overhand knot works well, ensuring it’s large enough not to pull back through the hole. Guide the other end of the cord through the opening in the starter housing and then through the pull handle. Tie another secure knot inside the pull handle. Once both ends are knotted, gently pull the cord out completely, then allow it to retract. If it doesn’t retract fully, the spring might need more tension. To add tension, pull the rope out fully, then while holding the pulley, gently turn it clockwise (or counter-clockwise, depending on the design) against the spring’s resistance a half-turn or full turn at a time, until the rope retracts firmly without slack. Be cautious, as over-tensioning can damage the spring, and under-tensioning will leave the rope slack. Singe the cut ends of the rope with a lighter to prevent fraying.
| Component/Issue | Description/Solution |
|---|---|
| Recommended Cord Diameter | 5/32 inch (approx. 4mm) for John Deere JS60. |
| Recommended Cord Length | 80-100 inches (2-2.5 meters). Measure old cord if possible. |
| Common Cord Materials | Nylon or polyester for durability and abrasion resistance. |
| Knot Type (Pulley End) | Figure-eight knot or double overhand knot to secure inside the pulley. |
| Knot Type (Handle End) | Overhand knot or fisherman’s bend to secure inside the pull handle. |
| No Cord Retraction | Spring needs re-tensioning. Follow the winding procedure carefully. |
| Hard to Pull/Jammed | Check for spring binding or debris inside the housing. |
Reassembly and final checks
With the new pull cord properly installed and the recoil spring tensioned, it’s time to reassemble your John Deere JS60. Carefully place the recoil starter assembly back onto the engine, aligning the bolt holes. Make sure the pull cord is not pinched or obstructed. Reinstall the bolts you removed earlier, tightening them securely but without over-tightening, which could strip the threads or crack the plastic housing. Give the assembly a firm tug to ensure it is seated correctly and doesn’t wobble. Before trying to start the engine, give the new pull cord a few gentle test pulls. The cord should extend smoothly and retract completely back into the housing without catching or binding. The handle should sit snugly against the housing when fully retracted. Once you’re satisfied with the pull cord’s operation, reconnect the spark plug wire to the spark plug. Now you can attempt to start your John Deere JS60 as you normally would. It might take an extra pull or two initially as the new cord and spring settle, but it should function just like new. Congratulations, you’ve successfully replaced your mower’s pull cord!
Replacing the pull cord on your John Deere JS60 doesn’t have to be a intimidating repair. By following a clear, step-by-step process—from gathering the right tools and materials to safely accessing the recoil starter, expertly installing the new cord, and finally reassembling the unit—you can restore your mower’s functionality with confidence. Remember the importance of disconnecting the spark plug for safety, carefully managing the recoil spring tension, and securing your knots properly. This DIY repair not only saves you the cost and time of a professional service but also provides a valuable sense of accomplishment. With your pull cord now operating smoothly, your John Deere JS60 is ready to tackle your lawn with renewed vigor, ensuring your yard work can continue without interruption. Enjoy the satisfaction of a job well done and a perfectly working mower!