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Introduction

Follow this guide to replace a worn or damaged throttle cable on the Honda FC600 tiller.

  1. Before you begin, it's important that you completely cut power to the tiller by disconnecting the spark plug. This will prevent the engine from accidentally starting up while you're working on the tiller. Grab the spark plug cap and pull it straight out to disconnect the spark plug from the engine. Grab the spark plug cap and pull it straight out to disconnect the spark plug from the engine.
    • Before you begin, it's important that you completely cut power to the tiller by disconnecting the spark plug. This will prevent the engine from accidentally starting up while you're working on the tiller.

    • Grab the spark plug cap and pull it straight out to disconnect the spark plug from the engine.

  2. Push the throttle lever all the way down. Push the throttle lever all the way down.
    • Push the throttle lever all the way down.

  3. Remove the 23 mm-long Phillips #2 screw securing the throttle lever to the handlebar.
    • Remove the 23 mm-long Phillips #2 screw securing the throttle lever to the handlebar.

    • This screw is accompanied by a square nut. Make sure to retain it for re-assembly.

  4. Use a pair of needle-nose pliers to remove the small clip attached to the throttle cable. Use a pair of needle-nose pliers to remove the small clip attached to the throttle cable.
    • Use a pair of needle-nose pliers to remove the small clip attached to the throttle cable.

  5. Grab the open end of the throttle cable and pull it out of the throttle lever to free it from its recess. Grab the open end of the throttle cable and pull it out of the throttle lever to free it from its recess.
    • Grab the open end of the throttle cable and pull it out of the throttle lever to free it from its recess.

  6. Continue to lift the throttle cable out of the throttle lever, making sure it clears the openings in the recess. Continue to lift the throttle cable out of the throttle lever, making sure it clears the openings in the recess. Continue to lift the throttle cable out of the throttle lever, making sure it clears the openings in the recess.
    • Continue to lift the throttle cable out of the throttle lever, making sure it clears the openings in the recess.

  7. Use your fingers to unscrew and remove the wing nut securing the air filter cover to the air filter elbow.
    • Use your fingers to unscrew and remove the wing nut securing the air filter cover to the air filter elbow.

  8. Lift up and remove the air filter cover to reveal the air filter. The air filter cover will still be attached to the tiller by a flexible hose. You can push the cover to the side while you continue to work on the tiller, or follow the next two steps to completely remove the cover.
    • Lift up and remove the air filter cover to reveal the air filter.

    • The air filter cover will still be attached to the tiller by a flexible hose. You can push the cover to the side while you continue to work on the tiller, or follow the next two steps to completely remove the cover.

  9. The next two steps are optional, but they will make it easier to work on the tiller from here on out. Squeeze the metal clip on the inside of the air filter cover and remove it.
    • The next two steps are optional, but they will make it easier to work on the tiller from here on out.

    • Squeeze the metal clip on the inside of the air filter cover and remove it.

  10. Hold onto the air filter hose and pull on the air filter cover to remove it. Hold onto the air filter hose and pull on the air filter cover to remove it.
    • Hold onto the air filter hose and pull on the air filter cover to remove it.

  11. Use your fingers to unscrew and remove the wing nut securing the air filter to the air filter elbow.
    • Use your fingers to unscrew and remove the wing nut securing the air filter to the air filter elbow.

  12. Wear gloves or use a rag during this step, as the air filter is coated with oil. Lift the air filter straight up off the elbow, making sure it clears the threaded rod.
    • Wear gloves or use a rag during this step, as the air filter is coated with oil.

    • Lift the air filter straight up off the elbow, making sure it clears the threaded rod.

  13. Use a 10mm socket and socket wrench to remove the 25.5 mm-long bolt securing the air filter elbow to the tiller.
    • Use a 10mm socket and socket wrench to remove the 25.5 mm-long bolt securing the air filter elbow to the tiller.

  14. Use a 10mm socket and socket wrench to remove the two nuts securing the air filter elbow to the carburetor's threaded rods.
    • Use a 10mm socket and socket wrench to remove the two nuts securing the air filter elbow to the carburetor's threaded rods.

  15. Use a pair of snap ring pliers to loosen the spring hose clamp on the breather tube, pulling it out 2-3 cm so it's not clamping onto the end of the tube. Use a pair of snap ring pliers to loosen the spring hose clamp on the breather tube, pulling it out 2-3 cm so it's not clamping onto the end of the tube. Use a pair of snap ring pliers to loosen the spring hose clamp on the breather tube, pulling it out 2-3 cm so it's not clamping onto the end of the tube.
    • Use a pair of snap ring pliers to loosen the spring hose clamp on the breather tube, pulling it out 2-3 cm so it's not clamping onto the end of the tube.

  16. Pull the air filter elbow straight off, making sure it clears the carburetor's threaded rods. As you remove the elbow, you may need to use your other hand to remove the breather tube from the engine's valve cover.
    • Pull the air filter elbow straight off, making sure it clears the carburetor's threaded rods.

    • As you remove the elbow, you may need to use your other hand to remove the breather tube from the engine's valve cover.

  17. Insert a flathead screwdriver in between the release tab and the tip of the cable tie securing the throttle cable to the handlebar. Twist the screwdriver to separate the release tab and loosen the cable tie. Repeat this step for the remaining cable ties.
    • Insert a flathead screwdriver in between the release tab and the tip of the cable tie securing the throttle cable to the handlebar.

    • Twist the screwdriver to separate the release tab and loosen the cable tie.

    • Repeat this step for the remaining cable ties.

  18. Pull the throttle cable out of the cable holder underneath the handle column. Pull the throttle cable out of the cable holder underneath the handle column. Pull the throttle cable out of the cable holder underneath the handle column.
    • Pull the throttle cable out of the cable holder underneath the handle column.

  19. Use a pair of needle nose pliers to bend the metal clip at the bottom of the handle column out and upward. Use a pair of needle nose pliers to bend the metal clip at the bottom of the handle column out and upward. Use a pair of needle nose pliers to bend the metal clip at the bottom of the handle column out and upward.
    • Use a pair of needle nose pliers to bend the metal clip at the bottom of the handle column out and upward.

  20. Use a pair of needle nose pliers to bend the last section of the metal clip outward to release the throttle cable. Use a pair of needle nose pliers to bend the last section of the metal clip outward to release the throttle cable.
    • Use a pair of needle nose pliers to bend the last section of the metal clip outward to release the throttle cable.

  21. Grab the end of the throttle cable with your fingers and push the cable inwards so that it lines up with the small cutout on the control lever. Lift the throttle cable straight up to free it from the control lever. Lift the throttle cable straight up to free it from the control lever.
    • Grab the end of the throttle cable with your fingers and push the cable inwards so that it lines up with the small cutout on the control lever.

    • Lift the throttle cable straight up to free it from the control lever.

  22. Grab onto the end of the throttle cable housing and pull it out of its holder on the control lever. Lift the throttle cable straight up to completely remove it from the control lever. Lift the throttle cable straight up to completely remove it from the control lever.
    • Grab onto the end of the throttle cable housing and pull it out of its holder on the control lever.

    • Lift the throttle cable straight up to completely remove it from the control lever.

  23. Pull the throttle cable all the way out,  fishing it through the clips, cable ties, and guides. Pull the throttle cable all the way out,  fishing it through the clips, cable ties, and guides. Pull the throttle cable all the way out,  fishing it through the clips, cable ties, and guides.
    • Pull the throttle cable all the way out, fishing it through the clips, cable ties, and guides.

Conclusion

To reassemble your device, follow these instructions in reverse order.

Craig Lloyd

Member since: 02/10/2016

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