Throttle cable install Q&A

[Runninn1]

Seems simple...I have wrenched on this bike since 86!
What's the shortcut to getting the throttle cable installed properly in the 'cam/chain assembly' on the handlebar?

However I try...I still have slack & it keeps trying to come out of the assembly.....

thanks

[Matt Chapter]

I think there were a couple of iterations of the throttle assembly.. I know that mine has two cables, and the ends slide into the slots on the chain part vertically.  Then you make sure the cables are run through the plastic housing correctly, then you set your throttle slack by rotating the grip and setting the gear onto the spool and teeth of the grip.  If I remember correctly there may even be a mark on the grip teeth to indicate the correct position.

Finally, you squint one eye, stick out your tongue, and put the cover back on without disturbing anything.  Note that if you don't get the cover over the chain slot widget correctly, it won't hold the cables in tightly enough.  The cover should sit flush without the screw installed.

Once you do that about three or four times, you'll get it, and it'll be time for a celebratory beverage. (As opposed to a wrenching beverage.)

[montmil]

Matt is correct. There are two almost invisible "scratch" marks that are to be aligned. These insure that the gear teeth are positioned correctly. It's that small junction block where the two cables meet the chain that can be annoying.

[davidpdx]

    You might also consider using a drop of service removable locktight on the screw. After changing my cable I didn't want to tighten it too tight onto the plastic cover and had the screw back out while riding. Luckily did not lose the top and got it reinstalled.  

[Bob_Roller]

Have you just replaced any parts in the throttle housing assembly  on the handlebar ?

[Barry]

....Finally, you squint one eye, stick out your tongue, and put the cover back on without disturbing anything.  

I haven't done it for a while but from what I remember that's an accurate description of the operation !

If the carbs have to be synced anyway I found adding some slack at the carb end of the cables helped.

[Runninn1]

I had just replaced them. One was frayed...can't understand why...it's just been 29 years!

Anyways, I remember back 10 years or so (I had them off for cleaning & float replacement) that you had to squint & stand on your head to get it just right.

I will look for those 'scratch' marks....thanks

[Bob_Roller]

Is the replacement cable the same length as the original cable
There are different length cables available .