| Author | Message | ||
     Egobuster1 |
Alrght i removed my frame to do some work to the bike and i have pretty much the hole bike back together mechanically just need to do some electrical wiring but i can't get the throttle to work correctly.. Alright guys after a couple hours of messing with this and routing the cables every which way possible and making sure theres no kinks I'm stumped. i tried just installing only the throttle pull cable and everything worked as it should but as soon as i put in the throttle return cable into the mix everything sticks and feels like its binding up. I took a bunch of pictures hoping maybe someone would be able to shed some light on the subject here as i really need it.  Here it is fully put together mine the rear cover.  throttle cable removed so you can see the throttle return cable.  Trying to show that the throttle return cable loops around on the back off the throttle tube (seems like friction could be a issue here)  just to make sure both look right And now this is how i have the cables routed and like i said with out the throttle return cable everything seems to be working just fine but once the throttle return cable is added into the mix both ways on the throttle stick very badly!  Up under the gauge cluster and the throttle return cable goes under the handlebars and throttle cable goes on top.  Down into the flyscreen.  Through the guide tubes.  From guide tubes back into the throttle body area.   Similar pictures basically looking from the throttle body back towards the forks. | ||
| M1combat |
I've found that the cable tension (or JUST barely a lack thereof...) on both cables needs to be perfect. I'd start there as long as you know there aren't any pinches or kinks. | ||
| Egobuster1 |
I think it has something to do with the throttle return cable some how is binding up or creating friction on the inside of the electronics box | ||
| M1combat |
"I've found that the cable tension (or JUST barely a lack thereof...) on both cables needs to be perfect. I'd start there as long as you know there aren't any pinches or kinks." | ||
| M1combat |
Your second and last pictures look a little suspect. In the second one it looks like the cable end isn't "quite" seated correctly. It may be just because you had just pulled off the other cable and it wasn't sitting right when you snapped the pic. In the last pic there is definitely a kink there as they lead into the throttle body bracket. So... Be sure the cables are right at the box on the handlebar and see what you can do about removing that kink. also... See above post. They need to be just right. When you have both installed and everything buttoned up and it IS binding... Does it release when you turn the bars to the left? (Message edited by M1Combat on February 18, 2014) | ||
| Egobuster1 |
I will try and fix that kink tonight. im going to get some cable lube and make sure the cable is lubed properly and re install it all. I will try turning the bars to the left and see if it releases but the thing is that its really hard to turn the throttle going both ways as if it takes a lot of effort. | ||
| Egobuster1 |
alright I've messed with this thing for countless hours again today and still can't get anywhere. the only thing i discovered was that the more tension i put on to the throttle return cable the harder it gets to twist in both directions. so I'm thinking maybe theres not enough free play in the cables and was wondering if anyone would be so kind to post of picture of behind there fly screen so i can see how theres is ran. | ||
| Egobuster1 |
Heres a short video of how I'm putting it together. Please remember I'm doing this with one hand while the other holds the camera so its a little shaky at times and i apologize in advance. http://youtu.be/Ju_6nwWR9NQ | ||
| M1combat |
You assembly procedure looks shaky but pretty much correct  . On my R I know the cables ends are in the right place when the two housings snap together all the way with no gap around the cross section where they split. I haven't assembled the front end of an S, but I know with my R that is the cables are adjusted even a small bit too tight or too loose it won't work quite right. It will bind until I turn the bars to the left, then the throttle snaps shut. I would assemble it all without the cover of the housing, hold the two cables where they need to be, adjust the "idle" cable to where it JUST starts to get a tiny bit of tension and then back it off a very small amount. Do the same with the throttle cable. Install the housing cover/other half. If it doesn't work fine I would loosen the idle cable a very small amount (maybe a 1/4 turn on the adjuster) and try again. If it still isn't working right tighten the idle cable to where it was and then loosen the throttle cable about a 1/4 turn. If it still doesn't work then loosen the idle cable 1/4 turn so they're now both loosened 1/4 of a turn from where you started. It could be that they're just routed wrong so you might also try to de-route them and just try running them out of the frame and just pretty much straight up to the throttle and see if they work fine that way. If they do you pretty much know the routing is the problem. I don't mean run them directly from the intake manifold, over the frame to the throttle... I mean from the intake manifold, through the frame like they're supposed to go but from there straight to the throttle without going through the flyscreen. Also maybe... Take the throttle grip housing off and just leave the two cables free, then rotate the throttle plate manually... Does it snap back when you don't have the ends in the grip housing? If so it's likely a cable tension issue. | ||
| M1combat |
Looking again though it really looks like the kink right as the cable gets to the intake manifold would be a problem. Also... I noticed there's a pretty good curve on the cable going around the ignition barrel. Can they go in the other side of that so they go pretty straight through there? Like I said I've never routed them on an S model so I don't know where they're supposed to go but both of those look a little suspect. | ||
| Egobuster1 |
I tried routing them straight from the intake out the frame and up to the grip and they still bind up badly. I think I need new cables because nothing that I do makes it any better so I removed the idle cable all together for now and tightened down the throttle pull cable and I'm just gonna try and get used to the bit of slack in the grip and when I have the money I made order new cables and try again | ||
| M1combat |
That tells me it is likely a tension issue. They can't be tightened down too much or too little. Each of those cause the same issue, just on different sides of the cable sheath. | ||
| Egobuster1 |
Yeah I had the adjustment knobs all the way lose and still wasn't working so I bought some cable lube and tried it and it did nothing too. | ||
| M1combat |
You're not hearing me. All the way loose is just as bad as all the way tight. | ||
| Brother_in_buells |
Maybe you have tried this already ,but how is the return cable working with both ends disconnected? ,is the inner cable moving free? | ||
| Egobuster1 |
I had to take it in to get some work done and they said the idle control cable was bad so I just had them fix it |
