Have you tried contacting your manufacturer? You have a fairly unique combo there that varies decently from out setups.

My first thought would have been extensive inspection and trial-and-error routing of the throttle cable, but your use of the kill switch and complete replacement of the throttle system seems to have eliminated that.

It just about has to be carb related as suggested already. 4-stroke singles are notorious for tuning difficulty when using carbs that are not CV or pumper...and I'm assuming that carb is not a pumper, as I know little about your model.

 

 

Hi guys.

Well i thought your input deserved an update.
I`ve made up my own throttle cable and (touch wood, fingers crossed) i think it`s sorted!
I`ve never liked the look of the two inner cables that i`ve had so far.Compared to the cables i fit to my bicycles they seem coarse, and more importantly (to me) are not stainless steel!
It was quite a simple job to file down a bicycle gear cable nipple to the size of the carb slide nipple and use a `repair` barrel nipple at the handlebar end.(I`ve got a Domino trials throttle assembly)
I thought the the throttle action was light and smooth before but it`s now super silky!
I`ve not changed anything else so that must be it.
Thanks again guys.

Cheers


Now to sort out my coolant leak, another odd one.Watch this space!

 

 

Cool idea on the bicycle cable application. That should work fine for the throttle since the pull stress is definitely less than a clutch cable. I'm also a mountainbike guy on the side, and some of the cable components for bicycles are very high quality.

My first comment on your issue made me think of a throttle issue but it seemed like you had eliminated it. And that application of the kill switch pushed it more toward carb tuning. However, I'm speculating the kill switch was lessening the slide pressure and allowing it to overcome your sticky throttle.

Good diagnostics there.

 

I made them for my Sherpa T, SR500 and MotoGuzzi using bicycle cable. Make 'em any length.

 

Slightly thinner and cheap as chips as well!