How to Replace a Throttle Cable on Vehiclesby Contributing WriterUpdated June 12, 2017
The throttle cable in a Vehicles runs from the top of the accelerator pedal through the firewall and out to the throttle body. As the accelerator is depressed it actuates the throttle butterfly on the throttle body allowing more air into the engine. If the throttle cable breaks the accelerator pedal will not function and the car will remain Vehicles an idle. If any part of the throttle cable is frayed or damaged it must be replaced immediately.
Under The Hood:
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Use a screwdriver to loosen and remove the screws that keep the scooter headset sealed. Open the headset top enough to be able to see inside and access the throttle handle. Locate the throttle cable connected to the handle rod. Identify the cable housing the cable inserts into to travel into the scooter body.
Open up either the scooter seat or scooter side panel by hand to access the carburetor. Locate the throttle cable and housing connecting to the top of the carburetor. Check to see if the old cable is already severed by tugging on it. Cut the old cable with cable snippers either at the carburetor or handle end. Grab the old cable sticking out of the housing and pull it completely out.
Throw the old cable away. Use a crescent wrench or screwdriver to open the top of the carburetor. Pull the top off to expose the throttle slide inside. Insert a new throttle cable end through the top opening from the inside out until the end with the lead stop on it is all that is left. Position the stop into the slide so that it hooks into the slide's cavity -- this feature allows the cable to pull the slide open for more fuel. Reattach the top back onto the carburetor body.
Take the free end of the carburetor and cover it with grease using your hand. Slather the entire cable except the very end. Insert the cable into the housing near the carburetor. Shove the cable into the housing until the other end eventually pokes out of the housing at the headset near the throttle handle. Line up the headset end with the pulley on the inside end of the throttle handle.
Attach a pinchbolt to the end of the cable in the headset once you pull it snug, removing any slack. Use a screwdriver to tighten the pinchbolt on the cable. Insert the cable and pinchbolt into the groove in the pulley on the throttle handle. Redo the process if it is not tight. Check that the pulley pulls the throttle cable correctly by pulling on the throttle handle once connected. Look at the carburetor and confirm the throttle slide is being pulled as well.
Reattach the scooter headset top and re-secure it by screwing in the screws with a screwdriver. Turn the scooter on and test the throttle to confirm the engine responds correctly when the throttle is pulled for more fuel flow.
Items you will need
New throttle cable
Remove the seat from the vehicle. Pull the front of the seat upwards to disengage the seat's mounting pins from the grommets on the frame. Pull the seat towards the front of the vehicle until the rear seat tabs are disengaged. Set the seat aside.
Remove the floorboard from the vehicle. Use a Phillips screwdriver to remove the screws around the perimeter of the floorboard. Pull the floorboard out and away from the vehicle.
Locate the inline cable adjuster on the throttle cable. Pull the rubber dust boot away from the adjuster. Twist the adjuster clockwise to loosen the tension on the throttle cable.
Unhook the throttle cable from the throttle pedal. Locate the opposite end of the throttle cable, attached to the carburetor under the seat. Use a Phillips screwdriver to loosen the carburetor's adjustment and pull the cable out from the carburetor's cable seat. Using a sharp blade, cut any nylon cable ties securing the throttle cable to the vehicle's frame or wiring. Pull the cable away from the vehicle.
Prepare the new throttle cable, twisting its inline adjuster clockwise to place the cable at its loosest position. Attach the cable to the throttle pedal and route the cable through the frame to the carburetor. Slip the cable end into the carburetor's cable seat. Tighten the adjustment screw with a Phillips screwdriver. Secure the cable to the frame with nylon cable ties.
Adjust the throttle cable's tension, twisting the inline adjuster counterclockwise to increase the cable's tension. Adjust the cable until the throttle pedal has between 1/16 to 1/8 inch of slack before opening the throttle. Push the rubber dust boot over the inline cable adjuster.
Reinstall the floorboard, using a Phillips screwdriver to tighten the floorboard screws. Reinstall the seat, sliding the seat's rear mounting tabs into the frame and pressing the forward mounting pins downward into the frame's rubber grommets.
Items you will need
Replacement throttle cable (Polaris part # 7080938)
Nylon cable ties
Place the vehicle in park and apply the parking brake. Shut down the engine, open the hood and disconnect the negative battery cable with the battery terminal wrench.
Grip the spring-loaded throttle actuator lever on the left side of the throttle body and rotate it counter-clockwise in order to release the tension on the throttle cable. Holding the actuator in place, insert the flat-head screwdriver behind the throttle cable retaining ball located on the end of the cable and pry it out of the actuator lever housing. Remove the throttle cable from the throttle body.
Reach under the dashboard above the gas pedal and pull the throttle cable toward the rear of the vehicle in order to create 2 to 3 inches of slack. Insert the flat-head screwdriver behind the throttle cable retaining ball near the top of the gas pedal and pry the ball out of the pedal housing. Slide the cable out of the gas pedal housing.
Pull the throttle cable through the firewall and out of the vehicle. Discard the old cable.
Complete the installation by reversing Steps 1 through 4.
Items you will need
Battery terminal wrench
Replacement throttle cable
Place the car in park and apply the emergency brake. Turn off the ignition and open the hood.
Locate the throttle body on top of the intake manifold.
Rotate the spring-loaded throttle actuator lever until the throttle butterfly is completely open. Pry out the throttle retaining bead on the end of the cable and remove the cable from the throttle actuator.
Crawl underneath the dashboard near the top of the accelerator pedal and locate the other end of the throttle cable. Pry out the throttle cable retaining bead from the top of the accelerator pedal and remove the cable.
Pop out the rubber grommet in the firewall that the cable passes through and remove the cable from the car.
Reverse Steps 3 through 5 in order to install the cable. Installation is reverse of removal.
Items you will need
Small flat-head screwdriver