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Discussion Starter #1
Hi all,

I'm currently on a road trip in Colombia on my KLR650 (2012, blue/white, all stock to my knowledge) that I bought here. I noticed today when I went to tighten up the free play on my throttle cables that the pull cable is frayed, almost completely severed. You never know but I figure I only have another day or so on this thing before it snaps. The problem is parts are limited and/or very slow to stock in shops here in Colombia, and I fear my chances of getting a replacement soon are slim to none.

Anyone know whether I Could switch the push and pull cables safely or reliably? Since the spring on the carb should push the throttle back automatically and the push caries a lot less stress, I figure this could be a good temporary option. Yes, I know it's not a great idea, not the safest, etc etc. the question is simply: can it be done? Miraculously the two cables actually appear to be roughly the same size. Need to do something about this ASAP - any help is much appreciated!!! Thanks

Dylan
 

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Men say it's been done--switching throttle cables.

I'd chance it, in your situation. You alone can determine the risk acceptability of running without a pusher cable.

Kawasaki does NOT install pusher/puller cables on ATVs with similar carburetors, pull cable only (EXAMPLE: KLF300, with CVK32 Keihin carb).

All this said; find a good bike shop with cable raw materials, and they likely can fashion you a replacement push/pull cable set.
 

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Men say it's been done--switching throttle cables.

I'd chance it, in your situation. You alone can determine the risk acceptability of running without a pusher cable.

Kawasaki does NOT install pusher/puller cables on ATVs with similar carburetors, pull cable only (EXAMPLE: KLF300, with CVK32 Keihin carb).

All this said; find a good bike shop with cable raw materials, and they likely can fashion you a replacement push/pull cable set.
Yes you can swap the cables.

And yes I would bet my own money that any good bike shop in Columbia can fix you up with a new cable in the old sleeve or send you to the place that can.

I recommend replacing both cables. It is the bending rather than the force applied that kills the cables. While your are at it consider replacing the clutch cable also. They all look good until they start to fray and then they go quickly.
 

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Discussion Starter #4
Thanks guys I will try it, see how it goes, then look for a decent looking bike shop along the way to get a new cable cut and clamped for me. Always a good idea to have spares - knew I forgot something when I left.
 

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I'd do it.
One cable only as the frayed one's gonna stick.
As mentioned many don't even have a push cable
and the failsafe is the thumb/kill switch.
 

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Discussion Starter #6
Unfortunately the cable housings are machined to fit exactly where they are on the throttle mechanism - cannot switch them there. The only thing I can think to do is switch them on the carburetor and operate the throttle in a reverse fashion. Sketchy... At best. Anyone have a better idea?
 

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I've been out there looking at the carb linkage and I don't
see much happening in the field. If the leaded end on the good
cable can be shaped with whatever tool you have is going to be the
answer. Trim, tap, rub on a rock, make it fit. The cable housings
are a tough one. Line them up without going into the slot? Hopefully
it'll be straight and not bind. This sucks cuz I have stuff and tools
here and can't do anything to help. Maybe "machine to fit" the housing
with the rock as a file/ sandpaper theory again. If it's too small it'll already
go in. Too big and rub it down is all I can come up with. Good luck and please
post progress reports!
 

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Discussion Starter #8
OK here's the progress report. I am at a farm house outside of a midsized town in mountainous Colombia. Unfortunately today is a holiday, and Colombians take their holidays very seriously, so finding an open shop was out of the question. As expected, the tattered pull cable snapped as soon as I starting playing with it. Also, let the record state that you cannot fully switch the push/pull cables on a Kawasaki KLR, as the throttle housing end are machined to fit next to each other in only one way. Switching around does not allow for the throttle mechanism to screw back together.

I took the old snapped pull cable out. I used the multitool I carry on my belt to carve a notch in the plastic "guider" at the end of the housing for the push cable at the throttle side, so that the cable can now bend back in the direction of where the pull used to sit without bending too much. All reassembled, I can now successfully operate the throttle in the correct way (I even tried assembling it back in reverse fashion - pushing forward to rev the engine!), but there is enough resistence with my rigged set up that the spring alone on the carb won't pull the vacuum closed now.

So, in the end, yes: you "can" do this, if you are totally shit out of luck. But its not safe. Tomorrow I'll be making the drive a few hours to the nearest big city in hopes they have a replacement cable, and I'll be doing so by manually closing the throttle back with my hand. Not proud of it but it will work.

Oh, and I tried the bicycle shop route: no one had any idea what I was talking about. Welcome to Colombia. Love this place but it sure is different.
 

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Ya' ought to try to ride a 3 wheeled ATV, with a 5 speed, Manual clutch, LEFT HAND OPERATION ONLY, Reverse Rotation Throttle, back in the '80s.

Actually, with a little 'thought and planning', it wasn't that bad.

The one-armed farmer/rancher, eventually was forced to purchase an Automatic transmission pick-up truck! About 2009! Caught speeding, after 40+ years of life with one arm!
 

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Discussion Starter #11
Wow, that sounds crazy. The interesting thing is, I ended up finding a shop I'm a different town that could indeed sell me a cable and a small, adjustable metal peg that slid onto the cable then tightened wherever you needed to anchor the other end - in this case the carb linkage. In spanish, FYI, this thing is called a "mica". From what I could tell the cable I bought was the EXACT same thickness and flexibility, and I didn't have a problem sliding it into the old housing, cutting it to the correct length, and reassembling the throttle. However, the throttle mechanism STILL does not spring back to a fully closed position with the spring on the carb, and I have to push the throttle closed with the push cable.

I used a little bit of WD40 to lube the cable when I slid it in the old housing, and at that point everything seemed to slide freely. But when hooked back in and connected to the carb I'm now getting a lot of resistance. Any ideas?
 
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