Variable Speed Cable

Removed broken cable and reversed process to install the new one.

Removed the grip control cover on handle and cover on front on the mower the cable literally snapped in and replaced the covers.

Dis- assembled the drive housing and found broken cable. Replaced cable, first by backing all previous cable adjustments out to maximum loosened and then fine tuned cable to correct tension and re-assembled drive housing. Worked just fine.
I then decided to change the blade. The old blade still cut ok but not perfect. I believe it was original blade. It had some pretty good nicks in it and was slightly out of balance although not bad. I have had mower for 4 years now and had only sharpened blade about twice a season. So overall had been sharpened 7 times. Always used flat file and a steel hone to sharpen but cutting area was getting smaller and a few of the nicks in the blade were large enough they couldn't be taken out. These were the cause of slight unbalance of blade. The new blade was balanced well but the factory cutting edge wasn't to my liking so I have the blade a few rasps with the file to make a little sharper. Checked balance and was in good shape. Installed the blade.
I then drained the oil and replaced with straight 30W semi synthetic oil, changed the air filters to new and added a new spark plug. Added fresh high octane gasoline and pulled the cord. Took two pulls to start but I've used the mower now for 2 weeks and it starts on first pull ever since. There's a lot less vibration and a nice more even cut. Mower also seems to cut a slightly larger area without stopping for fuel. Please note I bought this mower used to begin with but it was in almost perfect condition for a used mower at purchase. Overall age of mower is 11 years. I can't complain. Mower cuts and runs and self propels as good as a new mower. I can easily see this mower lasting at least 10 more years and maybe a lot more. For the parts I purchased from ereplacementparts they were in stock and about 1/2 the cost the local troy built dealers wanted for the same. Parts were here in 3 days. I could have bought my new filters from them as well for a great price but my line of work permits me to build my own at no cost.

I looked to see how the old cable was attached, then attached the new one just like the old one.

1. Removed existing cable housing and control cable.
2. Installed parts.
3. Added an extra spring to lower unit.
4. Tie wrapped control cable to handle

Removed front cover off of wheels
Removed cable from handle
Replaced cable with new.
Replaced front cover.

Made note on how the old cable was installed at each end, Then installed the new one in its place.

1. Removed the screws from the underneath side of the plastic housing on the lawnmower handle.
2. Removed the plastic housing at the front of the lawnmower deck that covers the drive belt and the cable.
3. Most time spent is cleaning grass clippings from underneath the plastic cover.
4. Removed the old cable from the plastic housing at the lawnmower handle, then removed rest of cable from the front.
5. Reversed the installation of the new cable, replaced the housing at the front, and the housing on the handle of the lawnmower.
6. Finally, adjusted the cable tension at the handle.

1 Remover cover and cable in handle end. (phillips screw driver)
2 Replaced with new cable at handle end and reassembled handle.
3 Removed variable speed self propelled box on mower deck. (socket screws)
4 Removed old cable and replaced with new cable partially attached a t mower handle.
5 Replaced cover.
6 Secured cable from mower deck to handle with zip ties ( not included with variable speed cable).
Done.

Took off pulley cover with ratchet set. Used pliers to remove cable from the pulley engage. Then took a screw driver to take trigger component apart. Installed new cable and put everything back together. Took less than 20 min.