Misc

Ryobi 40V Mower Cutout Fix

I’ve had my battery-powered 40V Ryobi mower (model #40108) for a year now and have been pretty happy with it.  However the last time I used it the damn thing would randomly shut off while mowing.  At the time there didn’t seem to be any rhyme or reason to the problem such as heavy grass or a weak battery which was reading 2/4 bars.  I threw the battery into the string trimmer and it worked great.

So I took the lovely slime-green plastic cover off to see if there was anything obviously wrong.  My hopes were low because I figured the mower would consist of a motor and control board.

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Simple mower internals

Sure enough nothing looked wrong such as a leaking capacitor on the control board.  But while putting it back together I noticed a kill switch I had never noticed before!  It’s located by the handle hinge, ensuring that the mower will only run while the handle is in the folded-out position.

This little switch was flopping around in its hole because one of the spring clips on the backside was broken probably while I was removing that slime-green plastic cover.  When the handle is folded out the switch is depressed, closing the circuit allowing the mower to run.

If you take a close look at the interaction between the switch and handle, it is  not a precision operation.  Due to the position of where the switch happens to be, the handle bumps into it, hopefully depressing it.  Here’s the root cause of my problem: The mower’s frame had loosened up over time, allowing the frame to rack from side-to-side during turns.  This racking let that little switch spring back up, opening the circuit and stopping the mower.

And thankfully the solution was to tighten these two T25 frame bolts, located right above the rear wheels.

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Keep these bolts tight

And as a footnote, I bypassed that dumb switch just to avoid this kind of nonsense in the future.  The connection was wrapped up with electrical tape after these photos were taken.

I hope this short article helps someone out!

27 thoughts on “Ryobi 40V Mower Cutout Fix

  1. This information helped me. The plastic handle clamps need to be securely fastened. I hope these plastic clips hold up over time

  2. Thanks for taking the time to write this! My mower was having the same intermittent issue. Yanked that switch out and hardwired it as well.

  3. After a few uses, my mower did the same thing. My Google searches all provided the same resolution you provided. I removed the cover of my mower and bypassed the switch. I went back to mowing and after a few minutes, the mower would cut off again so obviously the problem wasn’t the side handle switch. I opened the handle assembly where the bale and start lock switch are. I found that there is a small lever on the bale that engages the main power switch. The bale had enough play from side to side that the lever would not always press hard enough against the switch and the motor would shut off. With a lot of movement of the mower this would happen repeatedly. I tied a narrow cable tie around the end of the bale before it exits the handle casing and widens where the switch lever is to keep it from moving side to side. After reassembling the handle case it tested fine. No more spontaneous shut offs.

  4. I’m having the same problem with my Ryobi. No matter how many shims I put between the handle and the red button, it still quits.
    Can you tell me how you disabled that shutoff switch?

      1. Thank you David the bolt tightening you explained in the original post solved an issue that I just experienced!

  5. Great info. I put a piece of cardboard between the handle and the button and it worked just fine. Next project will be to splice the circuit closed, until cardboard!

    Thanks for the assistance.

  6. I am having the same issue, but I have the 20″ smart trek self propelled version. There is no red safety sensor along that bar. All other models seem to have it except mine. (I’m assuming it’s newer and they removed it after all these issues people are having). The manual only mentions a tilt sensor, but doesn’t say where and it only activates at a 45 degree angle. Please help! Model number is RY40LM03

    Thanks in Advance!

    1. If you figure out how to reliably reproduce the problem you should have an easier time of figuring out the problem. It is might be frame flex caused by loose fasteners

  7. My problem is with the propulsion system. While I can get power to the blade fine, when I pull the levers that are supposed to propel it, the lawnmower jerks forward then stops. The blade continues to get power. Any suggestions would be appreciated. Thanks.

  8. I have not used my new Ryobi lawnmower yet. The first time I used it the lawnmower starts and stops frequently. All the troubleshoot items were not the issue. I have the grass cut level on the highest level. The bolts on the side near the handles are tight. Any ideas?

  9. Help! I think I have a new model as well. 40v Brushless manually propelled. Bought in April from Home Depot. It cut off yesterday while mowing. The grass was a little wet as the sun had not hit that side of the house yet. Other than that I don’t know why it cut off. I don’t see the red button on the side and I’m not sure how to take the top off to investigate further. Any suggestions? Thanks.

    1. There are 12, I believe Torx #20 screws that hold the top cover and front bumper on. Removing them and then replacing the cover took more time than the fix. Also, the cutting height adjustment knob has 2 small Phillips head screws holding it on. Be careful – they are easy to drop and possibly lose.

  10. Had the same problem with my 1 year old Ryobi 40v push mower yesterday. A Google search brought me to Dave’s fix and…sure enough…it was the fabled red button switch. Jumpering the two wires together fired the mower right up, so I just spliced them together securely and went back to working and slaving over a hot lawn.

    Thanks, Dave!!!

  11. Thanks! That did the trick! Glad I started looking on line before I dove in with tools. It became a two minute fix.

  12. This worked. Because the spring bolts on the handle are difficult to pull out, I thought I’d leave them out since the handle seemed stable. After I turned spring bolts to secure handle, the mower worked. Thank you!

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