Throttle Lever won't rotate down to choke position

[Frank nKansas]

My Honda Mower: Harmony II HRT216 SDA, MZCG 6092719. Manual Choke.

With the throttle cable disconnected such that the inner wire can move freely, and even though there is still 3/4" of the wire exposed at the far end, the throttle lever does not rotate down passed maybe 30 degrees from its full down position.

I took the throttle lever assembly off of the mower, thinking I would take it apart to see what seems to be blocking the movement, but it doesn't seem to easily open up. And I don't want to break it. I've seen a couple of pictures and videos that briefly indicate the lever should be able to rotate down much further. And the user's manual shows a diagram of it in the 'choke' position, where it is almost all the way down. Mine seems to stop at the "Fast" position... perhaps a little further than that.

I've adjusted the cable clamp at the engine end to allow the choke to work, but, the throttle lever movement just doesn't seem right.

Has anyone else experienced this situation?

Thanks.

 

[slomo]

Lube the cable or replace it.

 

[Frank nKansas]

The cable wire moves freely within its outer sheath. And the throttle lever hits something solid within its enclosure. It feels like the assembly was designed to only allow that much movement.... I mean it hits something solid. The wire is clean and shiny- no rust at all.

Do you know whether the assembly can be taken apart without damage? I'm afraid it is glued together.

The mower does start up on the first pull. But it is awkward not knowing when the choke is fully open. I assume it should have some sort of indent or some indication that the choke is off.

Thank you for suggestion!

 

[slomo]

If the cable is good then the adjustment for the throttle slash choke is off. Download the engine manual for that mower. Read about throttle cable adjusting. Search on youtube as well.

 

[Frank nKansas]

It seems to be something internal to the throttle lever assembly. I can disconnect the carburetor end of the sheath and wire and remove the throttle assembly from the mower handle. The wire moves freely within its sheath. And the lever rotates freely until it just hits a stop. If I didn't know better, I would say that there is something wrong within the assembly. I'm just positive the lever should go down further than it does... But I have not found a good picture of the lever in the choke position. I am betting it should rotate down at a ~5 degree angle from the handle, but I can't be sure.

It seems to rotate to the point where the choke would come on, then it stops. Like maybe there is something broken inside where the indent or shoulder or something is to advise you that you now have the carburetor choked.

 

[Auto Doc's]

Have you tried a little more hand pressure on the lever to overcome the stop? This may be an intentional design issue to indicate where the choke would be activated. It also helps people realize when the choke is still on which would cause excess fuel use and spark plug fouling.

 

[Frank nKansas]

Have you tried a little more hand pressure on the lever to overcome the stop? This may be an intentional design issue to indicate where the choke would be activated. It also helps people realize when the choke is still on which would cause excess fuel use and spark plug fouling.

I agree that the 'stop' seems as though it would occur at the exact point you describe. And yes, I have pressed it hard. Even with the lever assembly released from the handle of the mower and with the carburetor end of the sheath released from its clamp and the wire disconnected from its termination point. The pressure I've applied makes me think if I pressed harder, I could break it. Makes no sense!

I'd like to hear how close the lever should be able to get to its 'visual' end point in the fully forward position.... Does it form less than a 5 degree angle? Obviously, what I'm seeing with the lever assembly is very unusual since no one seems to have experienced this phenomenon before.

Thank you for your comments and suggestions!

 

[Auto Doc's]

Being that it is an encased unit, I would see about getting a new one or one from a different mower. Throttle cables can be problematic at times because they will bend or kink inside the enclosure due to faulty sweep angle design of the lever.

If you look up the stock part you will likely find it has been superseded one or more times. That is what the manufacturer does to cover up their design flaws.

 

[Frank nKansas]

Yes. It appears the next step is to break it open and/or replace it. I am attaching two photos. One shows the lever all the way back and the other shows it as far forward as it can go.

Thanks!