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Throttle cables driving me nuts.

Discussion in 'Help Wanted' started by Electraglide1800, Mar 19, 2017.

  1. Electraglide1800

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    Mornin' all,

    Well finally got the old girl fired up yesterday after a partial strip down over the last few months.
    The final job is in theory the easiest one BUT it ain't panning out that way and is driving me nuts.
    It's the simple task of fitting and adjusting the throttle cables but the return cable just keeps on popping out at the grip end.

    The grip looks fine, the cables have been off the bike and thoroughly lubed, I've tried different tensions on each cable whilst reassembling but still the little b'stard keeps breaking free.

    Any advice/suggestions etc very welcome.

    The bike is a 2005 Chopper with just under 7000 miles.


    Thanks in advance for any replies,

    Rod.
     
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  2. BWG56

    BWG56 Guru

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    3 things comes to mind, are the cable tubes in the throttle pocket at the grip when you adjust, and is the ferrule on the end of the cable ball, I have repaired one that didn't have the ferrules, they were epoxied in.
    I don't know if the cables are different but maybe you got them switched if they are different.
     
  3. Electraglide1800

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    Hi, thanks for the reply, the tubes are pushed home in the throttle pocket, ferrules all present and correct and the cables are in the correct way round........................like I say..... it's driving me slightly nuts..
     
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  4. heybaylor

    heybaylor Active Member

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    maybe the throttle plate is the issue ?
    Disco the cables at the grip, then while holding both cables tight in your hands,
    pull one at a time, they should see-saw in your hand as the throttle plate moves
     
  5. Marky-Marc

    Marky-Marc Well-Known Member

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    So, if you have the ferrules in, the cables in the tracks on the grip, there is also a channel inside your hand control housing that goes over top of the grip/throttle wires....make sure that channel is clean, and make sure it is assembled correctly.
    Also, Make sure the wires to your PCB board are not interfering with the throttle cables when re-assembling.

    I've done it many times, and every time I always wished I had a third hand....

    Even if the cables are disconnected at the throttle plate, cables generally will not pop out of the grip-they stay in as long as your hand control is attached to the handlebars.

    It can be tricky at times, but if it is not put in correctly they will keep popping out. I did a video on it somewhere.....
     
  6. Electraglide1800

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    Whilst on the subject of throttle cables does anyone know whether there are Harley ones that'll fit as it's difficult getting hold of spares this side of the pond.
     
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  7. Electraglide1800

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    Thank you for that info, I'll have a dig around and check those suggestions out.
     
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  8. Marky-Marc

    Marky-Marc Well-Known Member

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    They are not Harley ones. They have a custom length to them, and each DOG model has a somewhat different length (some are the same).

    Curtis at wildsteedworx.com has most of the lengths figured out and will ship to England.

    Or if you know the length, you can have them made to length by various manufacturers....don't know about England though.
     
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  9. BWG56

    BWG56 Guru

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    I would think you would have to take them in and compare them.
    Also, I usually run a few rounds of tape around the master cylinder and handle bars to hold that half on the bars so you don't need the 3rd hand while separating them.
     
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  10. Marky-Marc

    Marky-Marc Well-Known Member

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    If your PCB board wires get underneath your throttle cable wire, when you twist throttle it lifts the wire out of the track on the grip....

    Also, MAKE SURE YOU ARE PUTTING THE FERRULES IN THE CORRECT WAY! If they are put in backwards (wrong way) BOTH wires will just slide out....
     
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  11. cdogg556

    cdogg556 Guru

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    I read somewhere he won't ship outside the U.S. now, not sure though.

    :agree: Yep, this is a must! :old2:
     
  12. 05 old dog

    05 old dog Well-Known Member

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    if curtis doesnt have them...and do try him first...you can call barnett clutch and they will make them...they have info on bike models....i have also heard they will repair a broken clutch cabel for free...send in your steel braided housing...
     
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  13. 05 old dog

    05 old dog Well-Known Member

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    and also right on the 3rd hand....what a design.
     
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  14. Electraglide1800

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    Cheers for the info my good men, much appreciated and I'll get on to their site a.s.a.p.
     
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  15. BWG56

    BWG56 Guru

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    I just had Barnett rebuild 2 of my clutch cables within the last 2 months, they charged $10 per cable plus return shipping and they were their cables.
     
  16. Electraglide1800

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    Thanks for all the advice. After successfully growing a third hand all is home, safe and secure (for the time being).
     
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  17. francoblay1

    francoblay1 The Spaniard

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    He does... he did send plenty parts to Spain for me. :oldthumbsup:
     
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  18. BWG56

    BWG56 Guru

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    Recently?
     
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