Handlebar swap - replace throttle/idle cables
#1
Handlebar swap - replace throttle/idle cables
Just about finished with Wild1 WO577B 12.5" mini-apes and Magnum Black Pearl handlebar and cable/line swap on 07 SG and thought I'd offer a tip on throttle/idle cable replacement.
Forum was helpful getting me there over Service Manual. Service Manual says "Drain/Purge, disconnect lines, release high pressure, lift/remove tank, blah, blah, blah...." PITA! Especially after removing entire exhaust to get to clutch cover for clutch cable replacement! Another member found a way to lift tank a few inches with 1x2/2x4" blocks, but NOT disconnect anything.
Here's one better: Forget about doing anything with fuel lines or tank!
Take a close look and you will see that throttle/idle only run about 10-12 inches under tank. Use a flashlight to see existing cable route from front and rear. The ONLY reason for removing tank is to run throttle/idle cables through the "b" (mounting bracket holder looks like a "b" bolted/welded to frame). The "o"/hole in the "b" is about as big as your thumb. PLENTY large enough for this trick!
After removing induction throttle/idle cable ends, tie strong twine/string to each cable end, several knots, just above ferrell. I tied one to each so that if one broke, I'd still have a pull string. Pull old cables, one at a time, out from the front. Tie twine/string to new cable and pull back in! Easy, huh? Just follow Service Manual from there to install induction and handlebar control sides and adjust throttle/idle cables BEFORE re-installing air cleaner/breather.
I have to think the H-D techs at the dealers are laughing at this one and a number of other tricks they use to get jobs done in minutes, while charging several hours labor!
Forum was helpful getting me there over Service Manual. Service Manual says "Drain/Purge, disconnect lines, release high pressure, lift/remove tank, blah, blah, blah...." PITA! Especially after removing entire exhaust to get to clutch cover for clutch cable replacement! Another member found a way to lift tank a few inches with 1x2/2x4" blocks, but NOT disconnect anything.
Here's one better: Forget about doing anything with fuel lines or tank!
Take a close look and you will see that throttle/idle only run about 10-12 inches under tank. Use a flashlight to see existing cable route from front and rear. The ONLY reason for removing tank is to run throttle/idle cables through the "b" (mounting bracket holder looks like a "b" bolted/welded to frame). The "o"/hole in the "b" is about as big as your thumb. PLENTY large enough for this trick!
After removing induction throttle/idle cable ends, tie strong twine/string to each cable end, several knots, just above ferrell. I tied one to each so that if one broke, I'd still have a pull string. Pull old cables, one at a time, out from the front. Tie twine/string to new cable and pull back in! Easy, huh? Just follow Service Manual from there to install induction and handlebar control sides and adjust throttle/idle cables BEFORE re-installing air cleaner/breather.
I have to think the H-D techs at the dealers are laughing at this one and a number of other tricks they use to get jobs done in minutes, while charging several hours labor!
Last edited by kdclaiborne; 05-21-2010 at 08:17 AM. Reason: remove last line
#2
#3
If I can save one poor sole from following service manual on this, I'll have contributed back 1% of what I've gotten from this forum! Seriously, most time was tying, cutting and re-tying string. Just pull out and pull back in. Might have to work 2nd cable back and forth a bit, but really nothing to it! I'm going back with radio and ignition panel/switch today, then front upper brake line. Next: drain forks and wait for black powder coat parts today/Monday, then put front end and front brake lines back together, some brake fluid. Done! Looks like I might get a couple of weeks to ride down here in Texas before we hit 100! Should have done this over the winter!
#4
I just worked with a friend to replace these cables on a Fatboy and although it sometimes took five hands we didn't remove exhaust but did un-secure tank so route cables. The bike we were working on we did not have a service manual for but my buddy is am Indy that just needed an extra couple hands so we got by.
#5
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