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Throttle Adjustment Issues
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1st Gear
Joined: Aug 2015
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From: Ontario
Throttle Adjustment Issues
Hey,
I'm new to this whole forum thing and have never used one before. So I apologize in advance if I'm doing something wrong. Anyways, I own an 07 sporty xl883l with a 1200 kit installed, with hi flow intake, and pro tuner. I recently changed my switch housing and in doing so had to losten off my throttle cables. To reset my throttle cables I researched the forums on here and was directed to a few different YouTube videos demonstrating how to do so. Followed everything to a Tee (I think) but am having a problem getting the butterfly to 90 degrees at full throttle. It's almost there but won't hit the stop and make that click noise. I run out of thread on the cable before that happens. Also when I'm at full throttle I can slightly go passed full and butterfly goes to 90 degrees. It's hard to explain but it's like I'm twisting throttle to full but if I force it slightly it will pop a bit further. Like tightening a screw to it's fullest and then just stripping it a bit. Same feel. If that makes sense? Is this normal? Any ideas why this is happening? Any ideas on how to fix it? Does it need to be fixed? Why isn't butterfly going to 90 degrees with normal full throttle? How do I fix that?
I'm new to this whole forum thing and have never used one before. So I apologize in advance if I'm doing something wrong. Anyways, I own an 07 sporty xl883l with a 1200 kit installed, with hi flow intake, and pro tuner. I recently changed my switch housing and in doing so had to losten off my throttle cables. To reset my throttle cables I researched the forums on here and was directed to a few different YouTube videos demonstrating how to do so. Followed everything to a Tee (I think) but am having a problem getting the butterfly to 90 degrees at full throttle. It's almost there but won't hit the stop and make that click noise. I run out of thread on the cable before that happens. Also when I'm at full throttle I can slightly go passed full and butterfly goes to 90 degrees. It's hard to explain but it's like I'm twisting throttle to full but if I force it slightly it will pop a bit further. Like tightening a screw to it's fullest and then just stripping it a bit. Same feel. If that makes sense? Is this normal? Any ideas why this is happening? Any ideas on how to fix it? Does it need to be fixed? Why isn't butterfly going to 90 degrees with normal full throttle? How do I fix that?
Throttle Adjustment Issues
I've never used the butterfly as an adjustment guide. Use the pulley on the front side where the cables attach. A correctly adjusted throttle will reach full throttle at the grip at the same time the pulley hits its stop. I would assume a flat butterfly, but never really looked.
From what you describe (not fully opening during adjustment, but overcoming some resistance while twisting the throttle), it sounds as if one of three things is happening:
A. Your return cable is too tight. This should be entirely slack while adjusting the main cable. Once the main is adjusted, adjust free-play with the return cable. The "correct" free-play is about 1/8", but I prefer less.
B. One of your cables is binding in the groove at the throttle. Loosen the top of the switch housing and see if it frees up the final bit of motion. If so, take the top off and check the assembly for correct installation.
C. The cables need lubrication.
Other potential issues:
The main cable is frayed, causing it to bind in the sleeve.
The cable routing is pinching the sleeve and causing binding. Turn your bars from stop to stop while twisting the throttle. Make sure that the routing isn't causing binding.
From what you describe (not fully opening during adjustment, but overcoming some resistance while twisting the throttle), it sounds as if one of three things is happening:
A. Your return cable is too tight. This should be entirely slack while adjusting the main cable. Once the main is adjusted, adjust free-play with the return cable. The "correct" free-play is about 1/8", but I prefer less.
B. One of your cables is binding in the groove at the throttle. Loosen the top of the switch housing and see if it frees up the final bit of motion. If so, take the top off and check the assembly for correct installation.
C. The cables need lubrication.
Other potential issues:
The main cable is frayed, causing it to bind in the sleeve.
The cable routing is pinching the sleeve and causing binding. Turn your bars from stop to stop while twisting the throttle. Make sure that the routing isn't causing binding.
Elite HDF Member
Joined: Aug 2011
Posts: 3,932
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From: Stockbridge GA
^^^^^^^All good stuff but the first line. I could really give a rats *** where the stop is. The butterfly is what lets air in, if its not completely horizontal your leaving potential HP on the table. Both my FI sportys were not horizontal, not off by much, but they were off. Thats one of the first "hot rodding" things I learned...........make sure your butterfly is COMPLETELY open at full throttle. Now if that coincides with hitting a stop.......cool, if a stop is preventing me from full throttle my file is coming out 
Throttle Adjustment Issues
I'd imagine you are 100% correct. I've just not done it that way. It's likely the stop is keyed to a fully open valve. Now I want to check.
One issue with not using the stop-adjustment method is this. A cable adjusted too tight will indeed stretch if twisting-slack is still available at the throttle when the stop is hit, then, the next time you adjust the cable, you have symptoms like the OP described.
One issue with not using the stop-adjustment method is this. A cable adjusted too tight will indeed stretch if twisting-slack is still available at the throttle when the stop is hit, then, the next time you adjust the cable, you have symptoms like the OP described.
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Thread Starter
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1st Gear
Joined: Aug 2015
Posts: 5
Likes: 0
From: Ontario
Throttle Adjustment
Tks allot everyone. I think I have the issue resolved. Tks to everyone's help. I did notice however that my throttle cable is slightly bent at the spring that works the butterfly. This is causing some of the issue as it was binding up there a bit. New cables next install. So I'm sure I will b on here with more questions regarding the install. Lol!!!
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