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Old October 7th, 2011, 09:03 AM   #1
headshrink
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Replacing throttle cable (AGAIN) - upgrade options?

This morning I discovered I need to replace my throttle cable for the second time. It is the cable that pulls the throttle closed, not open. The problem isn't with the cable itself, but rather the PLASTIC termination/adjustment point at the grip. Just like last year, the plastic split along the sleeve portion of the adjuster.

Does anyone know of a good upgrade option, so I don't have to replace it again next year (the part, not the bike)?

EDIT: I was mistaken... it is the OPENING cable, not the closing cable.
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Old October 7th, 2011, 12:19 PM   #2
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The plastic groove inside the grip is splitting apart? When the bike was ok, was there any play in the grip/throttle at all? I usually allow 1/4" of travel before the throttle opens, so it has plenty of slack.
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Old October 7th, 2011, 01:57 PM   #3
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Quote:
Originally Posted by CThunder-blue View Post
The plastic groove inside the grip is splitting apart? When the bike was ok, was there any play in the grip/throttle at all? I usually allow 1/4" of travel before the throttle opens, so it has plenty of slack.
It is the part outside the grip. Prior to breaking, and after, the free play is/was WNL. This is the closing cable, so it wouldn't affect the free-play like the opening cable would.

The only difference in performance is when I go WOT. The closing cable drags a little on the metal ferrule at the end of the cable housing, so the throttle doesn't snap closed as quickly/strongly. I can get a moment of racing RPMs when I shift, if I don't physically twist it closed. I usually do anyways, although when WOT, I find I typically shift smoother if I let it snap back (less distance for my wrist to cover). This may not technically be proper technique, but it works for me.

EDIT: I was mistaken... it is the OPENING cable, not the closing cable.

Here it is:
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Old October 7th, 2011, 03:00 PM   #4
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That's the adjuster that is just off the start/ kill switch box right? It sounds like the box needs to be adjusted so there's not so much tension on the adjuster.
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Old October 7th, 2011, 04:14 PM   #5
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Quote:
Originally Posted by CThunder-blue View Post
That's the adjuster that is just off the start/ kill switch box right? It sounds like the box needs to be adjusted so there's not so much tension on the adjuster.
Yes, I think we are talking about the same one. I just snapped a picture of it (below), but it doesn't look like there is much room to bring it in anymore. I know there is lateral preassure on the plastic fitting from the tight curve of the cable. I was pretty careful last time to install it exactly the same way as the origional.

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Old October 7th, 2011, 04:29 PM   #6
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Mine has the same issue....

CheapCycle parts has it on BACK ORDER so it must be a problem
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Old October 7th, 2011, 04:55 PM   #7
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Mine has the same issue....

CheapCycle parts has it on BACK ORDER so it must be a problem
Grrr..... I was just about to order it too. I was mistaken on which cable. It is the OPENING cable, not the closing. I'll edit my origional post in a moment.

Edit: I just checked, and the opening cable seems to be available. It is the closing cable that is on B.O.
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Old October 7th, 2011, 07:22 PM   #8
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You could check with Motion Pro if they have throttle cables available for the Ninja 250. If not they'll make you custom cable in whatever length you need.
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Old February 8th, 2012, 01:59 PM   #9
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Talking How long is the cable?

This is off topic, but hopefully you can answer a question that Kawasaki.com or dealers, etc. can't answer. I'm going to change my handlebars to an mx tube type bar for a more upright ergonomically riding position. For me to have new longer cables made, they need to know length. No one has OEM cables in stock to measure - SOOOO, while you have your old throttle cable off or your new one in hand - could you measure it for me? Pleeeeease!

Don't want to have to take my cables off just to measure. Down time for riding is un-exceptable.(ha)
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Old February 8th, 2012, 02:21 PM   #10
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I'll try to remember that. I have a new closing cable in the mail right now.
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Old February 9th, 2012, 05:05 AM   #11
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You must REALLY be putting a lot of torsion on the housing. I have mine routed differently from the factory method; in order to fit the ZX-10R master cylinder, etc. Mine has very little torsion on the housing.

Maybe your bike is trying to tell you something with all the problems that you've had with it. Could it be time for a ZX-6R?
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