Cable and Fittings

Cable maintenance

NOTE: See Maintenance and Lubrication intervals charts. Cable maintenance is primarily concerned with preventing deterioration through rust and weathering and providing proper lubrication to allow the cable to move freely within its housing. 

WARNING: Cable routing is very important. For details of cable routing, see the cable routing diagrams at the end of this manual. Improperly routed or adjusted cables may make the motorcycle unsafe for operation.

1.      Remove the cable.

2.      Check for free movement of cable within its housing. If movement is obstruced, check for fraying or kinking of the cable strands. If damage is evident, replace the cable assembly.

3.      To lubricate the cable, hold it in a vertical position. Apply lubricant to the uppermost end of cable. Leave it in the vertical position until lubricant appears at the bottom. Allow any excess to drain and reinstall the cable.

NOTE: Choice of lubricant depends upon conditions and preferences. However, a semi-drying chain and cable lubricant will perform adequately under most conditions.

Throttle maintenance

1.      Remove the Phillips head screws from throttle housing assembly and separate the two halves of housing.

2.      Disconnect the cable end from the throttle grip assembly and remove the grip assembly.

3.      Wash all parts in a mild solvent and check all contact surfaces for burrs or other damage. (Also clean and inspect right-hand end of the handlebar.)

4.      Lubricate all contact surfaces with a light coat of lithium soap base grease and reassemble.

NOTE: Tighten the housing screws evenly to maintain an even gap between the two halves.

5.      Check for smooth throttle operation and quick spring return when released and make certain that the housing does not rotate on the handlebar.