Broken Throttle cable
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Seasoned HDF Member
Joined: Feb 2007
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Broken Throttle cable
I was touring and as I was loading luggage on bike to depart the bike would not start.
It would crank but not start.
1998 Road King Classic with fuel injection.
After reviewing the situation I noticed zero throttle tension.
The pull cable snapped at the ball within throttle clamp enclosure.
This was the original factory cable.
It had been raining off and on for several days while riding.
There was a huge storm the entire day before and although bike had a cover it seems like moisture finally pushed the old compromised cable to give-up the ghost.
I opened the clamp, removed all tension at the adjusters from both the pull and push cables in order to switch over the good push cable to pull cable position.
Removed air cleaner cover, air cleaner, breathers and backing plate in order to transfer cable at throttle body.
There was a little strategy required in removing throttle body tension with one hand while trying to mount cable into position but all went well once I figured that out.
Maintenance folks at hotel were very nice, gave names of shops, offered tools but i had what was needed.
I made sure to disconnect the broken cable at throttle body end too in order to avoid binding.
Zipped tied the broken cable to good cable just to keep things clean and professional looking.
Took about 1:15 in the parking lot in order to confirm diagnosis and complete job.
Then left for several more days of riding.
It was a Sunday with no shops within about 1 hour so having tools and reading about how to do it here on the forum before saved me significant down time and money.
I was very fortunate that it happened in the safety of a parking lot and not on a road with no shoulder.
If you ride a bike with 2 throttle side cables it might be a good idea to learn how to do this in case of an emergency.
You need to have the correct tools too.
A cell phone and free towing might have not resolved the problem for two days since many mechanic shops close Sunday and Monday.
Also keep in mind that if you ride mountain roads the cell phone coverage is many times not available.
I ordered new cables and will change both..maybe toss old good cable in the saddle bag just in case.
I have since learned that some companies sell a little barrel looking end with small bolt that can be used to repair a cable if it snaps at ball...no idea if it works but maybe someone else has used it.
It would crank but not start.
1998 Road King Classic with fuel injection.
After reviewing the situation I noticed zero throttle tension.
The pull cable snapped at the ball within throttle clamp enclosure.
This was the original factory cable.
It had been raining off and on for several days while riding.
There was a huge storm the entire day before and although bike had a cover it seems like moisture finally pushed the old compromised cable to give-up the ghost.
I opened the clamp, removed all tension at the adjusters from both the pull and push cables in order to switch over the good push cable to pull cable position.
Removed air cleaner cover, air cleaner, breathers and backing plate in order to transfer cable at throttle body.
There was a little strategy required in removing throttle body tension with one hand while trying to mount cable into position but all went well once I figured that out.
Maintenance folks at hotel were very nice, gave names of shops, offered tools but i had what was needed.
I made sure to disconnect the broken cable at throttle body end too in order to avoid binding.
Zipped tied the broken cable to good cable just to keep things clean and professional looking.
Took about 1:15 in the parking lot in order to confirm diagnosis and complete job.
Then left for several more days of riding.
It was a Sunday with no shops within about 1 hour so having tools and reading about how to do it here on the forum before saved me significant down time and money.
I was very fortunate that it happened in the safety of a parking lot and not on a road with no shoulder.
If you ride a bike with 2 throttle side cables it might be a good idea to learn how to do this in case of an emergency.
You need to have the correct tools too.
A cell phone and free towing might have not resolved the problem for two days since many mechanic shops close Sunday and Monday.
Also keep in mind that if you ride mountain roads the cell phone coverage is many times not available.
I ordered new cables and will change both..maybe toss old good cable in the saddle bag just in case.
I have since learned that some companies sell a little barrel looking end with small bolt that can be used to repair a cable if it snaps at ball...no idea if it works but maybe someone else has used it.
Thread Starter
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Seasoned HDF Member
Joined: Feb 2007
Posts: 6,088
Likes: 1,128
From:
The ball broke from pull cable end .
I disconnected the throttle body end (engine side) and handlebar side during swap over in order to prevent broken cable from causing a tangle.
Basically disconnected and removed the broken cable from service at both ends and re-allocated good capable ends in its place at both ends.
I think it required two torx sizes at grip end and i believe the same allen/hex for air filter cover, breather bolts and air filter.
A couple of zip ties kept everything neat as broken cable cover was zip tied to functional cable just to keep things neat although broken cable was totally disconnected at both ends.
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