Throttle Cable Zip Tie Mod - DIY

[8gauge]

k, i took a look at the pics at the beginning of this thread and it looks like the zipties were filed down at the ends at a 45 degree angle. correct me if i'm wrong. maybe that'll do the trick...

[Nemesis]

Originally Posted by randomwalk101

I did this mod on the 08 250R (same thing applies to the pre-gen) with PCV pipe as pictured above. Mine is about 2/3 thick as KKIM pic. which is about 2 zipties. I think I'll take it apart (got another throttle tube of Ebay) and redo it with full thickness. I think it'll work...but I only use 1 pull throttle cable instead of 2. With the second cable in place, it'll bind. So I guess the trick is to remove the second cable. The second cable is there for backup in case the 1st one jams up..but that push cable isn't going to do anything I think if there other one "stuck"...test it out yourself..jam the other one with a plier or something preventing it from retracting...the "push" will do nothing. If anything, you can 1) hit the cut off switch button, or 2) grab the clutch or 3)turn off with the key.
Throttle cable failure without the second push cable is about 0.0001% so weight your risk/benefits wisely

I'm thinking of doing the same. I just found some precut PCV piping that fits the throttle tube perfectly.

So, how is the response so far? Better? The same? Have you come across any issues?

[streetracer744]

I have filed both of my ends down and trimmed the side in as well...But im still having slight binding at WOT is barley sticks for about 1 sec then goes down smooth..If i almost go WOT is never binds at all...ANy idea how to fix this?

[kkim]

make sure it's not your cables binding somehow and if that's not the problem, try using some slightly thinner cable ties.

[Betlog]

Originally Posted by streetracer744

I have filed both of my ends down and trimmed the side in as well...But im still having slight binding at WOT is barley sticks for about 1 sec then goes down smooth..If i almost go WOT is never binds at all...ANy idea how to fix this?

That's pretty dangerous, you might want to take that out until you fix it. Good luck.

[streetracer744]

im pretty sure its the actual pull cable...what is the cable ties?

[kkim]

cable tie= zip tie

[streetracer744]

i double checked everything is there is still little biding!...it only binds with the bike off if i twist it past WOT and if im riding it doesnt stick, catch or bind...WTF...should i remove push cable?

[kkim]

Originally Posted by streetracer744

...it only binds with the bike off if i twist it past WOT and if im riding it doesnt stick, catch or bind...WTF

huh??? how can that be?

hmmmm, okay... what makes you think the throttle is binding... is it an actual physical resistance at the throttle grip when you turn it to WOT? how can you turn it past WOT???

[streetracer744]

okay since the throttle requires less turning there is a little gap at the end of WOT that does do anything now...does that make sense?? its like a .2 inch play right at the end that if i go passed WOT it will stick for a sec and snap back...and if the bikes on and i rev it WOT it doesnt stick b/c i dont need to go passed to that .2inch play and even if i do it doesnt stick like when its off?? maybe the throttl line needs to be shortend at the carbs? my adjustment for throttle cable is already turned in all the way...If i loosen it at all my throttle binds/sticks more and more!!

[streetracer744]

and yes it deff the throttle cable binding b/c if i play with the line and the adjuster i can make it stick more/less or not at all for a few secs...... anyway I ordered the r6 throttle and will play with that!!

[kkim]

WOT = wide open throttle and should happen when the throttle is opened all the way to it's physical stop. Sorry, I don't understand what you're trying to say.

[streetracer744]

im saying the last .2inch of the throttle dont make my rpms jump any faster and also make it stick...my throttle is a shorter twist now so lets say WOT is a 1.5" twist it only takes me 1.3" to be at WOT..so the last .2" doesnt do anything and is where my cable sticks/binds...so im saying i dont need to twist all the wat to achieve full throttle!..sorry for the confusion

[kkim]

gotcha... do you have the proper amount of free play at the throttle?

[streetracer744]

not to much free play b4 I twist the throttle like it used to be. its very sensitive now and as soon as i twist the rpm move

[kkim]

You need to have some free play when the throttle is at rest. Sounds like the cable is adjusted too tight.

[streetracer744]

will check on that and loosen it up to see!

[setasai]

Mine barely has any binding but it's definitely tight. I dont see how I can adjust it to loosen it up at all though. I looks as if it's as loose as it can get. Will have to check again later.

[streetracer744]

ok so i got my r6 throttle today and its a shorter throw for sure..its a little less of a twist than the OEM tube w/ the zip tie mod..Id say about a 1/5 turn now w/ the r6 throttle..I love it but it still binds at WOT for a sec.... i have the throttle disassembled and have found that it the pull cable that BINDS! If i pull on just the line its self it still get stuck if i pull it out all the way...What can cause this?? is mt cable kinked some how? even with everthing taken apart the line catchs!!! ERR help!

[kkim]

have you tried cleaning and lubing the cable?

http://www.ninjette.org/forums/showthread.php?t=10016

what year is your bike?

[streetracer744]

2002... and no i have not cleaned the line yet but its the main pull throttle cable for sure.... its smooth all the way untill i pull the line out all the way untill it can move any more then it sticks for a sec

[kkim]

get a cable luber and shoot some wd40 through there and see what kinda crap comes out the end. be sure to put a rag on the end to catch whatever comes out so you can see what was in there.

if that doesn't fix it, then a new pull cable should solve your problem, if you are sure it's the cable that's binding.

[20ninja03]

Gonna have to try this mod. Thanks for the write up

[streetracer744]

its deff the cable and im gonna order a new one its only 13$$...I know this b/c even if the throttle is disassembled the cable still sticks by hand..IE the throttle tube isnt pulling the cable my HAND IS and its still sticking

[Liquidtoon]

I know this is in the pre-gen section but does anyone happen to know if the r6 (or any others) throttle will work on the 08+? I am thinking of giving the pvc method a shot just to see the result but would much rather a more professional style solution, just for safety if nothing else.

[setasai]

Originally Posted by Liquidtoon

I know this is in the pre-gen section but does anyone happen to know if the r6 (or any others) throttle will work on the 08+? I am thinking of giving the pvc method a shot just to see the result but would much rather a more professional style solution, just for safety if nothing else.

I believe it turns out the R6 and 08+ have close to if not the exact same size throttle tube so it doesnt end up changing anything.

[kkim]

Originally Posted by setasai

I believe it turns out the R6 and 08+ have close to if not the exact same size throttle tube so it doesnt end up changing anything.

that's what I've heard as well, but can't confirm it. But, if it is true... does this mean that pregen owners can gain a quick turn throttle by simply changing their throttle tube to a new gen one?

anyone have some pregen and newgen throttle tubes laying around to see if the outside diameters are different?

[nickadolph]

I was having trouble getting the zip tie to stick (they would both just pop off) so I tried using a cut closet rod mount and it's just slightly smaller than the throttle so it kind of clips on and stays. No need to hold it with pliers hoping that the glue will stick when you let go, just glue and walk away. Here is what I'm talking about. With the right piece just cut about 1/4" off the round part.

[wtfh4xx]

How are everyone's zip ties holding up?
I'd imagine over time the tie will wear down.

[CynicalC]

Originally Posted by wtfh4xx

How are everyone's zip ties holding up?
I'd imagine over time the tie will wear down.

It shouldn't really... They're plastic just like the throttle tube itself, and there shouldn't be any friction on it. It wouldn't hurt to check, but even if it started to wear through a little bit, which I *think* is unlikely, it wouldn't hurt anything.

[TFKninja]

Just a thought on this, I have my throttle tube off completely at the moment while I wait for a new handle bar, But was thinking Why not just cut a piece of irrigation pipe and file, like cut a thin bit off the end slice it or even take a piece out bevel the two edges at the required angle and clip it on even with the glue, may even be able to get different thickness with class ratings of pipe, It is only another alternative as irrigation is my occupation and it is readily available to me. if any one could think of any issues I could have with this, I'd be interested.

[choneofakind]

This has been covered on here somewhere already, I think by kkim. IIRC, it had to be just thin enough at the ends so that it didn't get stuck in the throttle control box, and had to be a smooth transition of thickness pipe so that it keeps the throttle pull linear...

[choneofakind]

it's actually on the first few pages of this thread. the pictures are down, but you'll get the idea.

[TFKninja]

Sorry If I was misunderstood, I was just looking at alternative material, this is ok isn't it, Pictures are better.

Hugs it well and is a natural shape. This a class 9 pipe, I hope the thickness is fine and it doesn't bind, I will assemble it before I glue it for a trial to see how it fits.

[choneofakind]

That looks pretty darn good!

any binding issues yet?

[hackeron]

Originally Posted by TFKninja

Sorry If I was misunderstood, I was just looking at alternative material, this is ok isn't it, Pictures are better.

Hugs it well and is a natural shape. This a class 9 pipe, I hope the thickness is fine and it doesn't bind, I will assemble it before I glue it for a trial to see how it fits.

Any binding issues?

[Nemesis]

FYI - this mod sucks.

[hackeron]

Originally Posted by Nemesis

FYI - this mod sucks.

Why does it suck?

[Nemesis]

Originally Posted by hackeron

Why does it suck?

Because when I attempted this some time last year I immediately experienced cable binding issues. Trailerboy experienced the same thing on his bike @ a trackday event last month. Granted he didn't have any issues prior but you may eventually experience this. Hopefully not during emergency situations.

I'm not a big fan of simple DIY homemade mods--I'm a direct fit kinda guy.

[alex.s]

Originally Posted by Nemesis

Because when I attempted this some time last year I immediately experienced cable binding issues. Trailerboy experienced the same thing on his bike @ a trackday event last month. Granted he didn't have any issues prior but you may eventually experience this. Hopefully not during emergency situations.

I'm not a big fan of simple DIY homemade mods--I'm a direct fit kinda guy.

+1!! we cut that stupid **** off cause its ****!