Hey guys I was changing the oil and doing some other maintenance over the past few days and noticed some of my allen bolts that hold some of the switches and brackets to the bars were getting rusty so i opted to buy some new ones. Anyway when I went to reassembly the throttle assembly when I tighten the top bolt on the case, the throttle basically locks up and I cannot turn it at all. See below pic for which top bolt I am talking about.



I took a look at the parts breakdown and I have all the parts required and made sure that guide piece was in there good. I do not have much experience with throttle assemblies.



Is there anything else dumb that I am missing? Should I not tighten that top bolt all the way or is there something misaligned in the throttle case? I guess I can take it apart and check again, but I am not really sure what is not aligning or not. As you can see from the first pic there is a little gap between the top casing, that gap does not close when I tighten the top bolt down either. It seems the throttle is only free to move with the top bolt tightened down a tad with the bottom one snug.

Thanks,

Anthony

 

Generally with all bar clamps (and axle clamps) you seat the top bolt 1st then tighten or snug the bottom screw, in your case that would eliminate that gap on top. Is the freeplay on the cables correct? you might have some extra slop in one of the cable not laying right?

 

Freeplay is good, The throttle assembly worked before i took it apart (prob should have just let it be! ), I took a few more pictures and took the assembly apart I think i know why it is not working, now i just need to know how to fix it lol. I think the close throttle cable is not seated correctly on the guide piece, therefore when i torque the top nut down it is pinching the cable between the throttle case and the plastic guide.

So now my question is, how the hell do you get both those cables on the guide and get that guide back into the bracket?? Is there some type of method to use, it is very tight in there! Maybe disconnect the cables from the carb first to give some extra space to work?

Two cables, i think the one in the back is getting stuck:


Guide piece, looks like the back cable rides on the indented area of the guide piece?



Thanks,

Anthony

 

Ok i answered my own question lol, thanks for the replies tho. Ended up taking the throttle cables off down by the carb, re-assembling the throttle case and guide with all the extra slack i needed now that the cables weren't being tensioned by the throttle return spring. After i re-assembled that i reconnected the cables to the carb, now the throttle tube spins free with no binding or sticking.

While i was there I also re-lubricated the throttle guide, it seemed there was some type of Vaseline on it to keep the cables moving nicely so i just re-applied some Vaseline.

I started this whole fiasco on my own as a result of proactive rusty bolt replacements. I guess the old saying "leave a sleeping dog be" is the lesson to be learned here. Oh well at least I know a little more about the throttle and cables on the KLX now.

 

you can service throttle without taking them loose from the carb, there's kind of a trick to it and you have to hold your tongue right

I made it easier by removing the return cable, trick there is make a new internal stop in the throttle handle so the pull cable will adjust up right.