Throttle Cable routing? - Kawasaki KLR 650 Forum
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post #1 of 9 Old 05-23-2012, 12:24 PM Thread Starter
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Throttle Cable routing?

Just picked up an 07 KLR650, and have just done the carb mod where the fuel screw plug was removed and adjusted out 2+, and picked up the needle with a washer, but in the process noticed that in some pics the throttle cables are mounted so that where they come out of the twist grip on the upper side of the handlebars, mine exit underneath? Which is correct or does it matter. Appears that the PO had it tip over on the right side and the cable routing put a small dent in the tank. Have the Dohickey on order, and may go ahead with a dynojet carb kit down the road. This ole gal is a real beast compared to my WRs and TTR.
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post #2 of 9 Old 05-23-2012, 01:26 PM
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Quote:
Originally Posted by Fruitfarmer231 View Post
Just picked up an 07 KLR650, and have just done the carb mod where the fuel screw plug was removed and adjusted out 2+, and picked up the needle with a washer, but in the process noticed that in some pics the throttle cables are mounted so that where they come out of the twist grip on the upper side of the handlebars, mine exit underneath? Which is correct or does it matter. Appears that the PO had it tip over on the right side and the cable routing put a small dent in the tank. Have the Dohickey on order, and may go ahead with a dynojet carb kit down the road. This ole gal is a real beast compared to my WRs and TTR.


Welcome to the forum!

Doesn't matter about the throttle cables. Some turn them upside down to get more slack for higher bars/risers.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #3 of 9 Old 01-03-2013, 03:31 PM
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I am trying to get my 94 Barbie back together to see if it actually runs. I reattached the throttle cables to the carb and the throttle handle. The carb opens but won't close. The cables on the Barbie are different than my 09 and I only have a manual for the 09. I've tried adjusting at the handle end and at the carb. No luck. Anyone have any helpful hints??? I know this is a really simple procedure, but I just can't get the cable right.

Thanks

Erik
2003 Bandit 1200S
2009 KLR 650

74 Honda CB360
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post #4 of 9 Old 01-03-2013, 03:43 PM
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Originally Posted by SteelB12 View Post
I am trying to get my 94 Barbie back together to see if it actually runs. I reattached the throttle cables to the carb and the throttle handle. The carb opens but won't close. The cables on the Barbie are different than my 09 and I only have a manual for the 09. I've tried adjusting at the handle end and at the carb. No luck. Anyone have any helpful hints??? I know this is a really simple procedure, but I just can't get the cable right.

Thanks

Does the carb close without the cables attached? The cable bracket should snap back closed when opened and released.

One cable is a pull cable and the other a push. Do they both move freely when not attached to the carb?

Be sure that they are hooked up right to the carb...

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #5 of 9 Old 01-03-2013, 03:59 PM
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Originally Posted by Spec View Post
Does the carb close without the cables attached? The cable bracket should snap back closed when opened and released. Yes

One cable is a pull cable and the other a push. Do they both move freely when not attached to the carb? Yes

Be sure that they are hooked up right to the carb...
They appear to be so

Should just be a matter of adjusting the nuts at the throttle end, right. The pull cable is on top, push on the bottom.

Erik
2003 Bandit 1200S
2009 KLR 650

74 Honda CB360
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post #6 of 9 Old 01-03-2013, 04:47 PM
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Originally Posted by SteelB12 View Post
They appear to be so

Should just be a matter of adjusting the nuts at the throttle end, right. The pull cable is on top, push on the bottom.

Yea just get the slack out of the cables.

The push cable is more of a safety thing. A vacuum carb could stick the slide somehow so the push cable ensures that you can close the slide manually.

I've run carbs with just the pull cable, danger is my middle name.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #7 of 9 Old 01-03-2013, 05:14 PM
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I am starting to think that maybe inside of the throttle housing there is an obstruction that is preventing it from returning to closed

Erik
2003 Bandit 1200S
2009 KLR 650

74 Honda CB360
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post #8 of 9 Old 01-03-2013, 06:55 PM
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Quote:
Originally Posted by SteelB12 View Post
I am starting to think that maybe inside of the throttle housing there is an obstruction that is preventing it from returning to closed
Had something similar on mine. The throttle was just slow to return. Turned out it was a small amount of grease between the throttle grip and handlebar that had semi hardened.
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post #9 of 9 Old 01-05-2013, 04:44 AM
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Farmerbud,
The general concensus is that Dynojet kits are
80 bucks worth of brass bits that will give you
10 mpg less and won't run one bit better. (ie: junk)

The standard carb mods are simple, Cheap, and effective.
Stock jetting is usually fine with the needle raised slightly
and the mixture screw backed out a half turn or so from stock.
It's a big mixer for a single and works nicely.


On a preference note: I put in a nice fat 150 main in for
insurance against high rpm leaning out. The main doesn't
see all that much service until ya whack the thing fully open.

My '09 gets 50 mpg or a hair better at times when I baby it around
the country roads.

Just another point of view.

This is my son, with whom I am well pleased." ----God
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