- Hey what's up, everybody.
Dustin here with Rocky Mountain ATV MC.
Today I'll be showing you how to replace
dual throttle cables on a dirt bike.
Alright, so today we're gonna show you how to
replace the throttle cables on a dual throttle cable design.
So the bike that we'll be working on here today
is a 2016 Husqvarna 501.
Now the process for changing out the throttle cables
on this bike is going to be about the same
for just about every dirt bike that's out there
that's got a dual throttle cable setup.
Now if your bike has a single throttle cable setup
and you're wondering how to take care of that,
we've got a really great how to video that will
show you how to replace and adjust the throttle cable.
So be sure to check that out.
Twisting the throttle on our dirt bikes
is a huge part of the thrill and experience
of riding your bike.
And when your throttle's operation isn't so smooth
not only does it cut into the bike's ride-ability
and performance, but it also makes it unsafe as well.
So keeping up on your bike's throttle maintenance
is to key to ensuring an awesome experience.
So replace the throttle cables on your dirt bike,
you're just gonna need a few basic hand tools.
Now keep in mind that the hand tools will vary
from bike to bike.
Now you'll definitely want to get some
cable lube and a cable luber.
So here we've got the Tusk cable luber
as well as the Motion Pro cable luber V3, and we will
be using the Motion Pro for today.
Now when it comes to replacement throttle cables,
Rocky Mountain ATV MC has got you covered.
We've got a wide variety of replacement throttle cables
including OEM and many after market selections.
So for today's video we're gonna be using
the Tusk replacement throttle cables.
And it's never a bad idea to always have
some safety glasses around as well as some rags.
Now when it comes to working on your dirt bike,
always be sure to reference your service manual
for proper procedures, torque specs, and safety information.
To begin, start by removing the seat.
And then you can remove the fuel tank.
Remove any cable ties or zip ties from the
routing of the throttle cables.
Next we can remove the cover that protects
the throttle cables on the throttle body.
Disassemble the throttle housing.
Disconnect the throttle cables from the throttle.
Disconnect the throttle cables from the throttle body.
Remove the throttle cables.
Now before we install our throttle cables,
it's always good to go ahead and give them some lube.
So today we're gonna show you how to use
the Motion Pro cable luber.
Now what's really cool about this is it's
a very well-sealed system.
So once you put your throttle cable inside,
it's designed to allow you to depress this plunger,
which will force feed the lube through the cable.
Now because this system is so well-sealed,
we don't have to depress this plunger, so we're
gonna slide this part of our throttle cable back.
We're gonna take the collar piece of the tool.
We're gonna slide it on like so.
Then we're going to install this little rubber seal
with the long taper facing towards the end of the cable.
Then we can take the body of it.
We're gonna push the throttle cable in, put the body
over it like so.
And then thread it together nice and tight.
Now once we've got this assembled, at this end
of the tool we can insert the nozzle for our cable lube
and begin to lube the cable.
And that's it.
That's how we lube our throttle cable.
So we'll go ahead and do this to the other cable
and once were finished getting it lubed, then
we can take it over to the bike and get it installed.
Wrap the new throttle cables through the
original routing, and if you're not sure how
they are routed, be sure to reference
your service manual for that information.
Next we can connect
the throttle cables at the throttle body.
Install the throttle cable cover at the throttle body.
Now before we reinstall our throttle cables, you'll
want to clean and inspect your throttle tube
and the throttle housing.
Given them a good thorough cleaning
with some contact cleaner.
If you have hand guards, be sure to remove them
so that you can remove the throttle tube.
Give the handlebar a good cleaning
as well as the inside of the throttle tube.
Now before installing the throttle tube
onto the handlebar, I like to take a little bit
of the cable lube and spray it onto the handlebar itself.
You can also spray just a little bit
inside of the throttle tube.
When I slide it on, I'll rotate it
just to make sure we have a nice smooth operating throttle.
Then you can reinstall your hand guard.
Now if you don't have hand guards
and you're reinstalling your throttle tube,
make sure to set it all the way onto the handlebar
so that it stops, it bottoms out.
Then you're gonna want to slide your throttle tube back
about five millimeters.
This way, we create enough room and create a gap
between the inside end of the throttle tube
and the end of the handlebar.
This way we can ensure that when we twist our throttle
we won't encounter any resistance.
Now when reinstalling the throttle housing,
it wouldn't even hurt to take just a little bit
of the cable lube and spray it on the inside here
where the part of the throttle tube will engage
the throttle housing.
Be sure to pour out any excessive cable lube.
We want to check to make sure that when
we twist our throttle, the rubber part of the grip here
won't make contact with the end of our hand guard.
That way, we don't run a risk of it getting stuck.
Now when adjusting the throttle cables,
you want to take this bottom one
and set it to where it is locked into place,
threaded all the way in.
And then for the top one we will make our adjustment
here so that we can achieve three to five millimeters
of free play at the throttle tube.
Now when doing this, be sure to have
the handlebars straightforward.
Now some dual throttle cables may have a barrel adjuster
at the throttle housing where you'll fine tune
the throttle's free play.
Now when making adjustments at your carburetor
or throttle body when it comes to your specific bike,
always be sure to reference the service manual
for specific procedures on how to do so.
Now once we have the tank and the seat reinstalled,
we're gonna take and turn the handlebars full right.
We're going to twist the throttle, let go of it,
make sure that it snaps back quickly
with no resistance to its starting position.
And also check for throttle free play.
Do this full right then full left.
Now the last test that we want to perform
to ensure that everything's in good shape,
we're going to start the bike, let it sit in idle,
and then we will turn the bars again full right,
let it sit at idle, full left.
Now if your idle is to change or go up an idle,
you will want to readjust the throttle free play.
And that's it.
That's how we change out dual throttle cables
on a dirt bike.
Now if you have any questions or concerns
as to what we've done here today, feel free
to leave us a comment below, and we'll be sure
to get an answer back to you.
Also, subscribe to our YouTube channel
for more product spotlights, how tos, and top fives.
Don't forget to check out our website
at rockymountainatvmc.com, where we have
the largest selection of parts, apparel,
and accessories for your motorcycle, ATV, and UTV.
I'm Dustin with Rocky Mountain.
Thanks for watching.
Keep the wrenches turning.