Broken throttle cable - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 5 (permalink) Old 07-30-2008, 01:09 AM Thread Starter
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Exclamation Broken throttle cable

I was running down the highway after a terrible round (+9) of disc golf this morning and my throttle was sticking. I played with it a bit and it let go. It would be fine if I din't turn it very far, but then if I pulled the throttle around more than 1/2 way, it would stick there and rev. I got it home, but by the time I did, it would not release at all.

After further inspection, it appeared as though the push (on return) cable had disconnected from the linkage. I then realized it wasn't moving when I rotated the throttle. The cable was catching on the carb linkage and keeping it from closing. I found that I could almost pull the entire length of the push cable out of the line.

Now that it is out of the way, the throttle seems to turn fine and not bind anywhere. Is this normal? If so, then what is the purpose of the push-pull type throttles? My only thought is for safety in case the carb linkage is gummed so you can force it closed.

Sorry for the long post, my questions really are:

1. Do I need the cable or should I cut it off. My first thought is that I should replace it.

2. If I do replace it, how difficult and are there any tips for making my job a bit easier?

3. Do I need to replace the pull cable too?

4. How hard is it to get the handlebar portion apart?

5. Do I just replace the inner cable and not the outer shield, or does the whole assembly get replaced.

TIA and sorry for the novel.

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post #2 of 5 (permalink) Old 07-30-2008, 07:11 AM
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I think it's more a safety thing too. Personally, I would replace it. And while I was at it, I'd do the other cable as well. It might be OK, but if the one went, the other might not be far behind. You could save the one that didn't break as a spare.
And being an '86, if they're original cables, it'd be a good idea to change both anyhow.
You'd need to change the entire cable, housing included.
Might want to also check and lube the choke, clutch, and speedo cable as well.

As for how tough it is replacing the throttle cables...... don't know..... haven't done that on the Vulcan yet.

AKA: Tim & 'The Adventure Cycle' VROC #24567, NEVROC, SteelCity VROC

"When life throws you curves,
Aim for the apex."

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post #3 of 5 (permalink) Old 07-30-2008, 06:00 PM
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Replacing the cables isn't hard per se. What's hard is manuevering the throttle linkage on the carbs so you can get the lead bead on the end of the cable in its proper place. There isn't much room in there and it is a game of patience. Small fingers help too.
Ron Ayers and Bike Bandit both sell the cables. They come with the outer shell as a unit since you would have to solder a new lead bead on one end or the other if you just replaced the cable itself and getting the length just right can be tricky.
The handle bar side is easy. It's only held on by two phillips screws. Once you split the plastic shell, the throttle cables are easy to get to. Just remember to replace one at a time or you get to sort out which is return and which is the throttle. The manual also recommends you use the old cable as a guide to thread the new one from the handlebar through the frame components.
Of the three carb cables, I have had the most problems reattaching the choke. It too is a game of being calm and patient. Getting pissed only makes it harder.

Jim W
93 VN 750 "Ursula"
Moved R/R 08Sep06
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post #4 of 5 (permalink) Old 07-31-2008, 05:19 AM
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Dennis Kirk sells some nice looking stainless covered cables, if you wanna add a little "bling". I don't remember how much they cost, and I don't know the difference in cost between those and stock replacements.
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post #5 of 5 (permalink) Old 08-01-2008, 03:50 PM Thread Starter
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I ordered some OEM cables from my local dealer yesterday. They are supposed to arrive on or before Thursday. I will be replacing them both and see how dextrous my fat fingers can be. I have a pair of really long needles nose pliers that might just become my new best friend.

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