Introduction

This is actually a reverse teardown -- a build-up, you could say -- of a Suzuki FA50's throttle cable. This was the best method I could think of to describe the stuck throttle cable problem I've been experiencing with my moped.

This teardown is not a repair guide. To repair your Suzuki FA50 Moped, use our service manual.

Image 1/1:
  • Here is the assembled throttle cable. It seems to be assembled correctly, but certainly does not function properly.

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Image 1/2: The only logical way for me to assemble these parts were: Image 2/2: Insert needle into gold-colored cylinder.
  • The throttle parts.

  • The only logical way for me to assemble these parts were:

    • Insert needle into gold-colored cylinder.

    • Insert retaining clip on top of needle.

    • Then compress and insert the spring (see following steps on how the spring was inserted).

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Image 1/1: The round, gray top screws into the carburetor.
  • The throttle cable without any parts.

  • The round, gray top screws into the carburetor.

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Image 1/1: I first use a pair of needle-nose pliers to compress the spring as much as I can.
  • To assemble the throttle cable:

    • I first use a pair of needle-nose pliers to compress the spring as much as I can.

    • This allows me to insert the throttle cable into the gold-colored cylinder without having to meddle with the spring too much.

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Image 1/2: The alternate view (picture 2) shows how everything looks internally. Image 2/2: After the throttle cable is in place, I let go of the spring into the cylinder.
  • I attach the throttle cable to the bottom of the gold cylinder and then route it through the cylinder's side slot.

  • The alternate view (picture 2) shows how everything looks internally.

  • After the throttle cable is in place, I let go of the spring into the cylinder.

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Image 1/2: When I twist the moped's throttle, the throttle cable goes inwards. I believe this is the desired action for the cable. Image 2/2: There are two problems, however:
  • I'm simulating screwing on the throttle to the carburetor by compressing the gold cylinder against the gray cap. As you can see, the spring compresses, and the throttle cable pops outward.

  • When I twist the moped's throttle, the throttle cable goes inwards. I believe this is the desired action for the cable.

  • There are two problems, however:

    • Nothing pushes the throttle cable back out when I release the moped's throttle.

    • The throttle needle does not move, but to my understanding it should go upward when I apply the throttle.

  • Please check out my Answers question if you can help me solve this problem! Thanks a lot!

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2 Comments

which way does you set the throttle when you put it in

ladell - Reply

It appears to be correctly assembled however the cable isn't bottomed out on the cup to allow for free movement, I think you may have put a flat spot in to the cable itself that's not allowing the cup to bottom out on it and giving you the return movement.

Ken James - Reply

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