I also installed new bars and a 1" raiser at the same time I installed the Mikuni, so I think the combo may have made the cables a little too short for my application.Took a ton of elbow grease and a few choice words to get the cables seated in the throttle assembly. I installed the cables on the carb first, and struggled with the throttle install BIG time. Step 3: Reconnect the throttle cable to the retaining bracket. Page 1 INSTRUCTION SUPPLEMENT FOR 1987- LATER YAMAHA YFM350 WARRIOR Removing stock carburetor and cables. ë,_o «uqq -�Š( ZÅâ–HKËÀ$:ÀÎ@vPÌÀ Ì ÀÊäÁø�Á˜I�qƒƒS1ÓYæ,!ÌǘW1f1Ú1ÌeÒbdac`´beÔ`”aøÍp…É�é7ç+�6Îkl'¹8yØ_±Ÿáß.tŠS�‰™çÏk ” “ (Éó’ç5k­@,³ ó& ~v.ÓóR�ÜÄÎÀ™¤�x-@€ õGO¶ endstream endobj 9 0 obj <>>> endobj 10 0 obj <>/ExtGState<>/Font<>/ProcSet[/PDF/Text/ImageB]/Properties<>>>/XObject<>>>/Rotate 0/TrimBox[0.0 0.0 612.0 792.0]/Type/Page>> endobj 11 0 obj <>stream Slide the new cable through the slotted hole in the accelerator pedal. 2. This guide will instruct you on how to install a throttle cable into a Koso slide carburetor. Reinstall the throttle linkage rod to the carburetor. Step 2 Cut the stock cable tie from the frame, located above the front cylinder. 8. Because it is made of rubber, the O-ring will eventually harden and crack. Step 17 Go back to the carburetor and disconnect the NEW throttle cable … 10. Remove the two screws holding the top plate on the carburetor. Disconnect the negative battery cable with an end wrench. 3. Attach fuel line onto fuel inlet banjo and secure with stock pinch clamp. Page 2 4. You can purchase the correct throttle cable for the Koso carburetor from Buggy Parts NW by clicking this link. Insert the small end of the throttle cable through the brass fitting in the top plate. 4. Install the carburetor. Swap the original PUSH throttle cable to the PULL throttle cable. Start by installing the cable ends into the throttle body/carburetor and throttle cable housing. Wow, timely post! Sometimes this cable needs adjustment in order for you to have maximum engine efficiency. On the Stock Carburetor Remove the Air-Cleaner assembly so you can see the Throttle Control Mechanism. After the install was completed Bob made the one and only TV cable adjustment by twisting the throttle to wide open and back a couple of times. Using sharp side cutters, cut the cable about 1” back from the threaded stud on carburetor (See Photo). Thread the cable into the Wire Stop connector on the engine. Remove the throttle cable from the carburetor. Some models may use sheet metal clips; if so, remove the cables from the clip. All this sounds simple – until you have to adapt one to an existing Edelbrock, Rochester Q-jet, or Holley carburetor. How to Install a Throttle Cable into a Koso Slide Carburetor 1. Your throttle cable is now installed! Step 16 Push the NEW cable through the bulkhead and snap it into place. Re-install TM40 choke cable Bolt choke knob bracket to the top forward starter drive cover bolt. 7. Then insert the whole slide/spring/cable/top plate assembly into the carburetor. Remove throttle cable from throttle pedal and chassis. Disconnect the throttle cable from the throttle body (on the carburetor). ... Any tricks I should know about. Step 3: Remove the carb end assembly and throttle cable adjuster from the engine end of the new Lokar Throttle Cable. Push the new cable through the firewall and into the engine compartment. Place Edelbrock carburetor into manifold. Slide the black piece you removed in step 1 over the small end of the throttle cable end and move it up onto the black portion of the cable. 5. Step 3: Install throttle cable bracket on carb and then install cable … Then pull the cable through all the way up to the threaded stud. 11. Screw it on, so that there is slack in the cable clockwise. Retract the throttle arm slightly to create slack in the throttle cable; remove the cable from the carburetor assembly. But we’ve found several elegant solutions. FIX TRIX: It is advisable to clamp the fuel lines prior to removal. Step 2: Mount Firewall fitting in line with hole in clevis on throttle, or with hole in factory-type pedal. Re-use or get the carb support from backing plate to lifter block. Attach the top plate and tighten the screws. DO NOT REMOVE the ferrule if the cable housing is braided stainless steel! Turn the cable adjusters on the throttle grip housing all the way in, then turn each of them one turn out. The carburetor throttle stop comes from the engine builder calibrated to keep the butterflies from opening beyond 100 percent open throttle, so it isn't difficult to match to that. Remove throttle cable paying close attention to routing, as the new cable… You can purchase these screws for your carburetor here.). I have already removed the old ones but for the life of me I can't decide what has to be done to connect them to the carburetors. Slide the cables' barrels into the valve catches and twist the throttle tube slightly to check that the valves open and close properly. Clean the carburetor mounting surface on both the intake manifold and the carburetor, and place a new carburetor base gasket (not included) onto the intake manifold. Remove the two screws holding the top plate on the carburetor. Throttle Cable will be installed into the larger of the two holes in the upper tab of the Lokar Throttle Cable Bracket. 6. Fig. 9. This device converts throttle movement into voltage that can be easily monitored by the transmission as throttle position. Install threaded stud onto the carburetor bracket. Release your grip on the spring and allow the spring and plastic piece to lock the cable in place inside the slide. 1. �QgĞ9uí¨4Ùr°ådËÁ–“-›¥§…§¥§…§µÔš��–��V©š�vñdF‹Œ–-2Zf´Èh™Ñ"£cF‡Œ��¹r9ò8ğ8ò8ğ8280³²}>B��ĞGà#ôøˆ<7aÆåȆzÍ÷+x¿Âì˹fd—Ç™Bvyœ'dWfWdWò+ø•ü Insert the curved pin at one end of the cable through the eye on the engine throttle assembly. Entire article contents copyright 2009 Buggy Parts NW, How to Install the BPNW Intake Riser on the GY6 150cc Motor, How to Adjust the Valves on GY6 150cc Motors, You can purchase these screws for your carburetor here. Push the throttle interlock lever back down. I have the gas tank off, radiator hoses out of the way. A spring is attached to one leg of the L, and the eye for the throttle cable is on the other leg. 4. Throttle Cable Installation Step 1: Install throttle pedal in desired location. Remove the black piece covering the brass fitting at the top of the carburetor. 2. Install the opposite ends of the throttle cables to the carburetor or throttle body, tightening the threaded ends of the cable guides into the cable bracket completely. Remove choke cable from dash. H‰\”ÉŠÛ@E÷úŠZv/M¯^µA. Hold the top plate and spring assembly in one hand. 1. Diameter of hole in firewall should be 5/16". Note: Be sure the NEW cable is routed in the same path as the OLD cable. This carburetor requires a different style throttle cable than is normally found on a stock buggy. Loosen the nut that secures the manual throttle lever so that the lever can move freely. Make sure fuel petcock is in “off” position. 3. and fasten the end of the conduit with the bracket. Push the black piece from Step 1 down over the cable and brass fitting and twist it until it covers the base of the brass fitting. Remove engine cover and tunnel (center of floor board). Unscrew and remove the carburetor assembly from the throttle cable. şçJ¨±WI�ÖTä¬P[Ñ?h¸Gg¡õÂÂ|õus›¦ĞÒËgdéetq×û¯/Í8Œ&TáŠ> W÷ endstream endobj 12 0 obj <> endobj 13 0 obj <> endobj 14 0 obj <>stream Remove the black piece covering the brass fitting at the top of the carburetor. How to Install a Throttle Cable into a Koso Slide Carburetor. Remove the fuel lines from the carburetor. Throttle Linkage adjustments (cable or rod): While holding the choke plates open turn the throttle linkage by hand to release the fast idle cam from the screw then release the throttle lever. QQ˜øO¸y�§»yÚ´ÃÑ?Gñ¯©õSןÍÓßíáÙćÛ8~ø‹ïg“˜õÚ´şŒ~ÔãÏúâM¼”½ìÛp¿›ï/¡æ{Åû}ô&[æ)aš¡õ×±nüT÷gIø­MQ…ß:ò}ûß}MXv<5ÿê)*Ò2,N‘pm×a^}ÏWa�%ËAµ@¿R¿B¯¨—õoÔoĞ[jøf;ê4÷CĞÜ/Q‘s¯{å)u Image 3: Remove two screws from top... 2. Compress the spring to allow the cable end to extend through the plastic piece at the end of the spring. Make sure the throttle cable is seated properly inside the handle and rejoin the two halves of the handle back together. Note that the Throttle Cable is attached to the small hole in the carburetor throttle arm, not the large hole with the bushings. Remove seat and gas tank. Upon successful cable routing, begin the reassembly process. See fig 1. Pull the OLD cable out of the bulkhead into the engine compartment. Figure 2 B. Connect the throttle cables to the carburetor bell crank by first installing the closing cable, then the opening cable (Figure 3). Pull the inner wire out of the cable housing. Locate the conduit bracket on the engine. As he did so the detent cable … Step 2:Place the Throttle Cable Bracket on top of the new carburetor base gasket, with the upper and lower tabs on the left. Step 8 Insert the cable you just cut into the adjustable end piece as far as possible and then lock it down with the 5. ~%¿‚_ɯàWò+ø•ü Images 4 & 5: Remove spring and slide assembly. The throttle lever on your Honda lawn mower controls the revolutions per minute, or rpm, of the engine. The throttle lever is connected to a cable that runs to your carburetor. INSTALLING THE NEW CARBURETOR 5. H‰\”Ín£0…÷)‹ùѤó œRˆ�E޾>œ¨•&ñ±ğ=şøo÷»}ßÍ&ş= ÍÁÏæÔõíä¯Ãmj¼9ús×GifÚ®™³å¿¹Ôc‡âÃı:û˾? Philips Screwdriver or metric Allen wrench. 2. Re-route the cables under the frame (Figure 2). (Note: In the images in this tutorial, we have replaced the philips-head screws with socket head screws for easier access and removal. Reattach the handle molding cover. Loosen the nut securing the throttle cable assembly to the carburetor. Use a quality gas filter before the carb inlet. Step 2: Hook the new cable up to the accelerator pedal. Step 1: Push the new cable through the firewall. Now adjust the rod or cable until you have some free play. Move the master control lever back to the "STOP" position. The throttle assembly is be located by identifying an L-shaped lever bolted to the engine housing. A faulty O-ring will allow air to leak into the carburetor assembly, which will cause the engine to run lean. Remove 3 screws on left (driver) side plate Open the throttle - stick your finger inside to keep it open to slack the cable The cable is held in by a brass retainer in the cam - lift it out and note how it works as you have to put it back later Work the end of the cable out of the cam Push the new throttle rod into the seat on the trigger. Be careful to not tear the gasket between the carburetor body and top plate. Gently remove the top plate and lift out spring and slide assembly. Unscrew the wing nut on the air cleaner lid and remove the air cleaner housing. Then things can get complicated and sloppy. Tighten the nut that holds the choke knob to the bracket Attach … 3. Fuel line may need to be trimmed to proper length. ~%¿‚_ɯàWò+ø•ü The throttle O-ring forms a seal between the throttle rotor and the throttle body. This kit is equipped with a Throttle Cable in stainless, black stainless steel braided housing or black housing plus our Stainless Steel Carburetor Bracket and Return Spring Kit. How do I install new throttle cables on a 1979 Honda CBX. Re-install any covers you removed to gain access to the carburetor. The smaller hole on the upper tab is for attaching a kickdown mounting bracket if needed. Install the throttle cable into the trigger, then re-install the spring and reposition the trigger on the mounting pin. Duo-Pak only available for carbureted applications with Holley, Edelbrock, AFB, Quadrajet and In-Line Dual Quad carbs. Insert the cable end into the aluminum slide piece and hook it into the small circular groove. Use masking tape and a felt pen to mark all vacuum hoses connected to the carburetor, including the throttle positioner diaphragm (if so equipped), or vacuum advance line. 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