Throttle Cable Removal
Throttle cables may be removed if they need to be replaced. The throttle cables may also be removed to clear more room to work on the top engine. The throttle cables are removed when removing the Throttle bodies assembly.
Tools:
phillips screwdriver.
kerosene
powdered graphite
Do First:
Remove Foremans, ram air covers, tank cover, lowers and side fairings (FAIRING REMOVAL).
Remove Left Side Subframe. This will make removing the lower cable ends a lot easier.
Removal
1. Slide the rubber boot forward off of the throttle case over the black plastic throttle and throttle return cable guides.
Remove the two screws [TC] with a phillips screwdriver.
2. Remove the two halves of the throttle case allowing both of the cables to go slack.
3. Remove both upper throttle cable ends from the throttle tube. Note which
cable end goes to which hole in the throttle tube for reassembly.
4. Mark both of the cables ends and the throttle tube so that they may be easily reconnected.
5. Free the top end of the throttle cables from the wire cable retainer welded to the bottom of the front brake fluid reservoir bracket.
If you need to remove the throttle tube, take off the bar end weight and slide the tube off.
6. Locate the lower ends of the throttle cables where they connect to the throttle bodies.
Mark the lower ends of the cables as you did the upper ends in step 4
Remove both cables from the throttle bodies assy.
7. Release and unfasten the retainer spring as shown. It is not necessary to remove the bracket from the throttle bodies assy.
With the retainer unfastened, remove the lower throttle cable ends from the bracket.
8. Pull the lower end of the throttle cable ends out from the left side of the engine compartment. Guide the top end of the cables over the triple tree.
Continue to guide the cables under the air box back into the engine compartment.
9. In order to bring the upper ends of the throttle cables into the engine compartment, it will be necessary to remove a plastic retainer ring (shown between the two large bolts in the picture).
The retainer ring is held into a hole in the plastic heat barrier wing above the radiator by a beak-like fastener. The beak needs to be pushed up through the hole one half at a time in order to remove the retainer ring. Squeezing the ring slightly into an oval shape can help to pull one half up while it is simultaneously pushed from below.
Installation
10. Route the upper cables from the left side of the engine compartment, over to the right side of the black plastic heat barrier wing between the radiator and engine compartment.
Rout the cables over the right side of triple tree (see pics, step 8).
11. Install the cable retainer ring to the throttle cables and heat barrier wings (see pics,
step 9).
13. Rout throttle cables behind the front brake line and through the wire retainer bracket on the front brake fluid reservoir (step 5).
14. Install the lower cable ends to the spring wheel on the throttle bodies assy (step 6) according to how they were marked during removal.
15. Clean the inside of the throttle tube and the handle bar with kerosene and wipe dry.
Lube the bar with powdered graphite or a very thin film of white lithium grease.
Slide the throttle tube onto the clipon bar.
16. Install both upper throttle cable ends to the throttle tube (steps 3 and 4, reverse procedure).
17. Lube both halves of the throttle case with powdered graphite where the inside flange of the throttle tube rolls.
Place the rear half of the throttle case onto the bar arranging the black plastic throttle cable guide and the flange of the throttle tube inside.
The small pin [P] fits into the adjoining hole in the handlebar.
18. Place the rear half of the throttle case onto the clipon bar so that it adjoins the front half (step 2, reverse). The throttle return cable guide is arranged into the rear half of the throttle case.
19. Insert the screws into the throttle case. Tighten the screws that hold the throttle case together with a phillips head screwdriver (step 1, reverse).
20. Fit the lower throttle cable ends into the bracket on the throttle bodies assy (step 6, reverse).
Fasten the spring clip retainer over the lower ends of the throttle cables (step 7, reverse).
Install Foremans, ram air covers, tank cover, lowers and side fairings (FAIRING REMOVAL).
* Last updated by: Rook on 12/31/2017 @ 11:13 PM *
