Trying hard to hook up the throttle cables at my handlebar. Cannot fit it in so the plastic housing closes.?

Question

I have tried for a long time now, I got the bike running good, Ninja 750R, 1989. But I can't hook the throttle cables up. The plastic housing does not fit on. With the engine kill switch and starter button. It has a front and back plastic side. I have tried literally everything, I got it to fit when not on the handle (just to see) but it will not fit when I put it on. What gives? I know I am using the correct procedure?

Answer 1

Run out of Inner Cable,,and can't pull it thru far enough to go into throttle handle??

Most all those Dual Cable throttle things are like that.

Throttle must be assembled/installed with cable Disconnected from Carb Linkage.

Try disconnecting it from the Carbs,
then assemble the throtlle on the bars,
and re-connect the cable to the carb linkage.

You'll need to leave a distinct amount of "slack" in the cable.
Not much,,,but the throttle grip should have a small amount of free-play.

Turn the Bars in both directions and make sure the throttle slack remains.
If Not,,that indicates the cable is in a bind somewhere ,
and turning the bars is pulling on the cable.

Once you're all done,,and tank is back on & everything,,,Check Again.
Make sure the freeplay still exists with bars turned in both directions.

You shouldn't have any problem with that,,but you DO need to double check & verify all is OK.

Hope that helps

Answer 2

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Answer 3

--Cables completely off the bike.
--Route them from hand grip, around front of steering neck.
--Attach cables to carbs (leave lock nuts loose and cables off of clamps).
--Insert one cable through handle bar switch and connect both cables to twist grip.
--Close handle bar switch and tighten screws.
--Check that twist grip works properly.
--Install cables on carb clamps and tighten lock nuts.