Throttle tube removal / disconnect tips? - Wrist Twisters
 
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post #1 of 8 Old 03-12-2014, 06:44 AM Thread Starter
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Throttle tube removal / disconnect tips?

Is there a trick to disconnect the throttle tube from the cables? I just want to reroute the cables from a different point in the headlight stay so that I can mount higher bars. I have the throttle assembly off the current handlebars & no matter how much slack I induce in the cables, I cannot get the tube off. Am I missing something?

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post #2 of 8 Old 03-12-2014, 06:54 AM
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If you just want to get the tube off the handlebar the handlebar needs to be removed to get the right angle/slack to get it off. If you're trying to disconnect the the cables from the cam/tube I'm pretty sure it's the same as the clutch cable, or most cables for that matter. Just rotate it until the cable lines up with the slot and pull out the metal end piece to detach. I'm not sure if I'm answering the question you're asking

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post #3 of 8 Old 03-12-2014, 07:05 AM Thread Starter
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Quote:
Originally Posted by badmoon692008 View Post
If you just want to get the tube off the handlebar the handlebar needs to be removed to get the right angle/slack to get it off. If you're trying to disconnect the the cables from the cam/tube I'm pretty sure it's the same as the clutch cable, or most cables for that matter. Just rotate it until the cable lines up with the slot and pull out the metal end piece to detach. I'm not sure if I'm answering the question you're asking
I have already done the first part of your 2 part suggestion The handlebars are off the bike.

I am trying the second part where you suggest to line up the cables with the slot, unfortunately that is not happening. I have taken throttle tubes off before on a no. of bikes & they are relatively easy to do.

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post #4 of 8 Old 03-12-2014, 07:16 AM
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Adjust the slack at the throttle bodies. Disassemble the the tube housing (that has the starter button). I was able to wrestle the lower cable off from there. A bit of twisting, removal of the brake lever, and plenty of cussing let me get the top cable off. On the bottom cable, try to push it to the side to get it off the cam. That is what got me the slack I needed. I would have not been able to do it without first adjusting the slack at the intake. Yes, those 10mm nuts are a pain in the ass to turn. Maybe 1/8 to 1/16 of a turn at a time.

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post #5 of 8 Old 03-12-2014, 08:34 AM Thread Starter
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Quote:
Originally Posted by beefsalad View Post
Adjust the slack at the throttle bodies. Disassemble the the tube housing (that has the starter button). I was able to wrestle the lower cable off from there. A bit of twisting, removal of the brake lever, and plenty of cussing let me get the top cable off. On the bottom cable, try to push it to the side to get it off the cam. That is what got me the slack I needed. I would have not been able to do it without first adjusting the slack at the intake. Yes, those 10mm nuts are a pain in the ass to turn. Maybe 1/8 to 1/16 of a turn at a time.
Thanks, I will try that. I was afraid it would come to this. I hate working on the throttle bodies for anything.

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post #6 of 8 Old 03-12-2014, 09:06 AM
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At least you don't have to remove the TB... but part of TB removal is disconnecting the throttle tube!

If you don't have the service manual, it's probably worth looking at.

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post #7 of 8 Old 03-12-2014, 09:46 AM Thread Starter
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Quote:
Originally Posted by beefsalad View Post
At least you don't have to remove the TB... but part of TB removal is disconnecting the throttle tube!

If you don't have the service manual, it's probably worth looking at.
Already looked at it & found no pointers on just removing the throttle tube. Which is why I asked here

I like Suzuki's design a lot better. The cables connect to either the left most or the right most throttle plate, thereby working on it a lot easier. Compared to shoving it down the middle of the TBs & make life miserable for us.

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post #8 of 8 Old 03-13-2014, 07:08 AM Thread Starter
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OK I got this out without touching the TBs at all. Just make sure you completely max out the freeplay in your throttle & that tube is NOT on the handlebar. This will let you twist the tube out of the housing without much trouble.

All good now

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