Join Date: Aug 2006
Location: Springfield, MO
Desperately need help with 1/5 throttle...
I got my 1/5 throttle spacer from Rifleman and tried to install it tonight. It came with no directions but in his PM, it had a link on how to install it. It looked easy so I gave it a try. I took apart the throttle housing and took off the cables and ground the tabs out of the housing…everything was going good.
Next I removed the tank which was a hard because I abused the wiring connector for the fuel pump trying to get it apart. I never could figure out how to take the fuel line loose from the tank though, so I set it on a chair next to the bike still attached.
Next, took off the airbox and thought I was going to break off the sensor in the back trying to twist and wiggle it out of there. It was a tight squeeze, but I got it out without breaking that sensor in the back…at least it did not physically look broke.
So now I have an open shot of everything. I get my laptop out and look over the installation pictures again because things just don’t look as I remembered them. Well, things are totally different. I guess those pics were off an ‘04-’05 and mine is a ’06.
There are only two slack adjusters on my cables and they are both located a few inches from the throttle. The pics show a couple by the radiator and a couple where they go into the throttle bodies, and I assume a couple more by the throttle where mine are located.
Well, I screw mine in all the way to get maximum slack and put the thing back together. Everyting goes together fine, but just as I suspected, the throttle was stiff and needed more adjustment, but I didn’t have any and no where to get any.
So next, I cut the plastic nut off one of the adjusters so I can screw the adjuster in further to get a little more slack. Well, that didn’t work because it bottomed out and wouldn’t screw in all the way.
In a final stand, I get out the hack saw and saw about 3/16 – 1/4 in inch off the threaded housing. I go real slow and saw a ring around it and when I get close, I take some pliers and break the end off so I don’t saw through and cut the cable.
Well, that part goes well, although time consuming. Now I have this ring of threaded tube around the cable that has to come off. It is too short to saw, so I get some dikes and cut through it. While in the process and straining my hardest to cut through the aluminum tubing, I finally break through and the piece falls to the floor.
Now im excited to put it back together and get riding. I get ready to screw the part back together and I noticed the 4-5 strands of the cable are cut and are fraying off. I put it all back together anyway and it was just the right amount cut off to make it work, but I am not going to take a chance putting a frayed cable back in there.
If it comes apart more and jams inside the cable, it could make it bind and cause the throttle to stick. So now I ordered a new throttle cable tonight.
I’m debating on giving it another shot, or else just throwing away the 1/5 conversion and going back stock. I just don’t know any other way to make it work and I don’t want to ruin another cable.
Has anyone did the mod on a ’06 and how did you go about doing it.
Here is the part I am really worried about…the throttle cable hooks on to the throttle bodies at the end on the clutch side and it is smashed tightly against the frame. There looks to be no room to work to replace the cables. I’m hoping the engine will not have to be pulled or I’m in trouble.
If anyone can give me any advise, please do…got the bike in pieces in the garage and want to get on the road ASAP.
Thanks in advance
PS…how do you take the gas line off the tank? Does it remove at the fuel pump or at the throttle bodies?