help: cable location below fuel tank

jaesun · August 19th, 2012, 05:36 PM

I removed my fuel tank to get to the carburetor. When I got everything back together, all appeared to be good. But I eventually noticed that there isn't enough slack for the throttle cable. If I turn to the extreme right, my throttle cable tightens and revs go up rapidly. It's not as bad when I got to the left.

I don't know where the actual location is for the throttle cable since my rubber damper on the front bracket for the fuel tank fell off when I lifted the tank. The cables just laid to the side of the bracket. I just assumed that all of the cables went above the bracket. I think I put all three on the right side above the bracket, and it's not enough room between the rubber damper and the frame.

Do any of the cables go above the bracket? Can anyone confirm this for me? I've been searching for photos and can't find any.

I didn't get the chance to remove the tank today, but I hope to get to this asap.

lgk · August 19th, 2012, 05:43 PM

my cables are between the motor and the frame well below the tank.

there should not be any tight bends for the throttle cables, if you are finding that the cable bends sharply anywhere after the triple clamp something is wrong.

jaesun · August 19th, 2012, 05:46 PM

Wow. Quick response.

I was kinda hoping that I wouldn't have to remove the tank, but it's definitely on my to do list now. I will rearrange the cables so they're below the front brackets for the fuel tank.

lgk · August 19th, 2012, 06:02 PM

i agree it would be quicker to remove the tank and refeed the cables.

just test the play in them before you put everything back together.

Lychee · August 19th, 2012, 06:43 PM

Diagram

jaesun · August 19th, 2012, 07:48 PM

Quote:

Originally Posted by Lychee

Diagram

nice.

jaesun · August 22nd, 2012, 04:30 PM

Update:

It's not the throttle. I removed the tank and found the clutch and throttle cables all tied together. I removed the zip tie so the cables were a little more free and then moved the clutch cable to below the bracket. I kept the throttle cables above the bracket just like in the diagram. When I move the handlebars, I don't see the throttle bracket on the carb moving at all.

I still have issues, but it's coming from the choke. When I go extreme left or right, either the RPMs will rev up or the engine is killed. I think it needs to be rerouted in front of the handlebar, but I had to end the troubleshooting because of a thunderstorm that was rolling in. I'll try to figure it out tomorrow. At least I know where the problem is coming from.

I also noticed that the left handlebar is slightly bent and wobbles a bit. So I'll probably have to replace that as well.

Lychee · August 22nd, 2012, 04:55 PM

Another Diagram.
If this doesn't fix it, maybe you need a new cable....

jaesun · August 22nd, 2012, 06:04 PM

Quote:

Originally Posted by Lychee

Another Diagram.
If this doesn't fix it, maybe you need a new cable....

I'm seeing where I can relocate the choke/starter cable. right now it's in front of the clip. From the diagram, it should be between the clip and fork.

These diagrams are a godsend. Where are they coming from? I really do appreciate the help.

Lychee · August 22nd, 2012, 07:04 PM

Quote:

Originally Posted by jaesun

I'm seeing where I can relocate the choke/starter cable. right now it's in front of the clip. From the diagram, it should be between the clip and fork.

These diagrams are a godsend. Where are they coming from? I really do appreciate the help.

The service manual

I am glad I could help. Welcome to ninjette.org!

jaesun · August 23rd, 2012, 05:32 PM

What humbling experience. Especially when I chipped my tank. Not sure if it's even a chip since it's only a small chip (about the size of a lower case "o" on a laptop screen). I saved it an will use some superglue to put it back on. It's right by the neck.

Update:

I messed around with the choke cable location. After about a half dozen variations (I had to remove the tank each time), I still had the engine revving with bars turned to the extreme right. I figured out that I get no movement in the choke bracket on the carburetor when the cable is below the frame/tank bracket.

I then noticed that the slight revving decreased with the throttle cables below the frame/tank bracket. But it was always there. It only disappeared when I moved the throttle all the way up so it clicked. I never realized that the throttle slightly clicks if you move it all the way up.

Well, this revving only occurs at idle. My guess is that under a load, I'll never have this issue. Just to be sure, I'll lube the throttle cable before I put everything back together again with the cables under the frame/tank brackets.

lgk · August 24th, 2012, 08:35 AM

did you reassemble the handlebar correctly?

jaesun · August 29th, 2012, 04:58 PM

I lubed the cables and now everything is good. I always made sure that the cable routing was clear. Thanks for all of the help!

August 19th, 2012, 05:36 PM	#1
jaesun ninjette.org member Name: Jason Location: Germantown, MD Join Date: Aug 2012 Motorcycle(s): 2013 Ducati Monster 796, 2005 Kawasaki Ninja 250R (sold), and 1985 Kawasaki GPZ900R (multiple winter project) Posts: 177	help: cable location below fuel tank I removed my fuel tank to get to the carburetor. When I got everything back together, all appeared to be good. But I eventually noticed that there isn't enough slack for the throttle cable. If I turn to the extreme right, my throttle cable tightens and revs go up rapidly. It's not as bad when I got to the left. I don't know where the actual location is for the throttle cable since my rubber damper on the front bracket for the fuel tank fell off when I lifted the tank. The cables just laid to the side of the bracket. I just assumed that all of the cables went above the bracket. I think I put all three on the right side above the bracket, and it's not enough room between the rubber damper and the frame. Do any of the cables go above the bracket? Can anyone confirm this for me? I've been searching for photos and can't find any. I didn't get the chance to remove the tank today, but I hope to get to this asap.

August 19th, 2012, 05:43 PM	#2
lgk ninjette.org certified postwhore Name: Jason Location: Norfolk, VA Join Date: Dec 2011 Motorcycle(s): 2012 EX250, 2014 EX300 Posts: A lot.	my cables are between the motor and the frame well below the tank. there should not be any tight bends for the throttle cables, if you are finding that the cable bends sharply anywhere after the triple clamp something is wrong. __________________________________________________ Ethioknight Memorial Fund- Sticker sale http://www.ninjette.org/forums/showthread.php?t=111700

August 19th, 2012, 06:02 PM	#4
lgk ninjette.org certified postwhore Name: Jason Location: Norfolk, VA Join Date: Dec 2011 Motorcycle(s): 2012 EX250, 2014 EX300 Posts: A lot.	i agree it would be quicker to remove the tank and refeed the cables. just test the play in them before you put everything back together. __________________________________________________ Ethioknight Memorial Fund- Sticker sale http://www.ninjette.org/forums/showthread.php?t=111700

August 24th, 2012, 08:35 AM	#12
lgk ninjette.org certified postwhore Name: Jason Location: Norfolk, VA Join Date: Dec 2011 Motorcycle(s): 2012 EX250, 2014 EX300 Posts: A lot.	did you reassemble the handlebar correctly? __________________________________________________ Ethioknight Memorial Fund- Sticker sale http://www.ninjette.org/forums/showthread.php?t=111700

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August 19th, 2012, 05:46 PM	#3
jaesun ninjette.org member Name: Jason Location: Germantown, MD Join Date: Aug 2012 Motorcycle(s): 2013 Ducati Monster 796, 2005 Kawasaki Ninja 250R (sold), and 1985 Kawasaki GPZ900R (multiple winter project) Posts: 177	Wow. Quick response. I was kinda hoping that I wouldn't have to remove the tank, but it's definitely on my to do list now. I will rearrange the cables so they're below the front brackets for the fuel tank.

August 22nd, 2012, 04:30 PM	#7
jaesun ninjette.org member Name: Jason Location: Germantown, MD Join Date: Aug 2012 Motorcycle(s): 2013 Ducati Monster 796, 2005 Kawasaki Ninja 250R (sold), and 1985 Kawasaki GPZ900R (multiple winter project) Posts: 177	Update: It's not the throttle. I removed the tank and found the clutch and throttle cables all tied together. I removed the zip tie so the cables were a little more free and then moved the clutch cable to below the bracket. I kept the throttle cables above the bracket just like in the diagram. When I move the handlebars, I don't see the throttle bracket on the carb moving at all. I still have issues, but it's coming from the choke. When I go extreme left or right, either the RPMs will rev up or the engine is killed. I think it needs to be rerouted in front of the handlebar, but I had to end the troubleshooting because of a thunderstorm that was rolling in. I'll try to figure it out tomorrow. At least I know where the problem is coming from. I also noticed that the left handlebar is slightly bent and wobbles a bit. So I'll probably have to replace that as well.

August 23rd, 2012, 05:32 PM	#11
jaesun ninjette.org member Name: Jason Location: Germantown, MD Join Date: Aug 2012 Motorcycle(s): 2013 Ducati Monster 796, 2005 Kawasaki Ninja 250R (sold), and 1985 Kawasaki GPZ900R (multiple winter project) Posts: 177	What humbling experience. Especially when I chipped my tank. Not sure if it's even a chip since it's only a small chip (about the size of a lower case "o" on a laptop screen). I saved it an will use some superglue to put it back on. It's right by the neck. Update: I messed around with the choke cable location. After about a half dozen variations (I had to remove the tank each time), I still had the engine revving with bars turned to the extreme right. I figured out that I get no movement in the choke bracket on the carburetor when the cable is below the frame/tank bracket. I then noticed that the slight revving decreased with the throttle cables below the frame/tank bracket. But it was always there. It only disappeared when I moved the throttle all the way up so it clicked. I never realized that the throttle slightly clicks if you move it all the way up. Well, this revving only occurs at idle. My guess is that under a load, I'll never have this issue. Just to be sure, I'll lube the throttle cable before I put everything back together again with the cables under the frame/tank brackets.

August 29th, 2012, 04:58 PM	#13
jaesun ninjette.org member Name: Jason Location: Germantown, MD Join Date: Aug 2012 Motorcycle(s): 2013 Ducati Monster 796, 2005 Kawasaki Ninja 250R (sold), and 1985 Kawasaki GPZ900R (multiple winter project) Posts: 177	I lubed the cables and now everything is good. I always made sure that the cable routing was clear. Thanks for all of the help!