The rip cord, also referred to as a pull string starter, on a 6.5 horsepower lawnmower engine turns a pulley, which engages the clutch and flywheel to begin the lawnmower engine. Every time you pull on the lawnmower engine rip cord to begin the engine, it rubs from the rewind starter assembly starter cord eyelet, which creates friction which wears the rip cord as time passes.Eventually, a weak, worn rip cord may break and needs to be replaced.

Drain any excess fuel in the lawnmower or shut the fuel shut-off valve, even if equipped. Pull the spark plug wire from the spark plug, situated either at the front or rear of the engine cylinder.

Pull the air filter assembly in the lawnmower engine carburetor, which typically requires removing one or two maintaining screws. Slide the air filter and air filter housing in the lawnmower engine carburetor.

Unscrew the fuel tank retaining bolts with a socket wrench. Lift the gas tank from the engine to get the compressor casing retaining bolts. You might have the ability to get the compressor casing without removing the fuel tank, based on the mower version.

Unscrew and remove the oil filler tube in the crankcase. Remove the control panel trim in the engine, generally located at the topthe side of the compressor casing.

Unscrew and remove the compressor casing from your lawnmower engine to get the rewind starter. Set the compressor casing on a flat surface for rewind starter assembly elimination. Some version lawnmower engine rewind starter assemblies are held onto the compressor casing with rivets, while some are held in place with self-tapping sheet metal screws. Unscrew the rewind starter finger guard maintaining screws using a screwdriver, if armed, to get the retaining screws or rivets.

Drill through the rivet heads using a steel drill bit and power drill to free the rewind starter assembly in the compressor casing, if required. Alternately, unscrew the self-tapping screws using a socket wrench. Eliminate the rewind starter assembly in the compressor casing.

Pull the rip cord out of this rewind starter assembly. Expand the rewind starter pulley cord hole using the rewind starter assembly cord eyelet. Expand a C-clamp onto the starter assembly and starter pulley to protect against the pulley spring in unwinding. Pull the rip cord knot in the pulley face recess using needle-nosed pliers, cut the knot and pull the cord out through cord eyelet.

Push the new rip cord to the rewind starter assembly cord eyelet and through the hole in the pulley groove. Pull the starter cord through the pulley hole and then out of the pulley face recess using needle-nosed pliers. Bend a knot onto the cord end; pull on the cord tightly to push the knot into the pulley face recess.

Push the opposite end of this new rip cord through the bottom hole in the rip cord handle and out through the top hole. Tie a knot at the starter cord end. Pull the starter cord tightly to seat it in the handle’s leading recess.

Loosen the C-clamp marginally to rewind the pulley and cord gradually into the rewind starter assembly. Pull the starter cord in the rewind starter assembly a few times to check for proper operation.

Set the rewind starter assembly onto the compressor casing, aligning the mounting holes using the compressor housing holes. Tighten the self-tapping screws using a socket wrench, if applicable. On rivet-equipped versions, rivet the rewind starter assembly to the compressor casing with sheet alloy rivets and a rivet gun.

Assemble the compressor casing and assorted removed parts onto the lawnmower engine in reverse order of disassembly. Start and stop the lawnmower engine to check for suitable rewind starter assembly surgery.