How to Replace a Harley Throttle Cableby Jim Murkot Sr.
Harley-Davidson motorcycles with carbureted engines utilize a dual push-pull system for their throttles. One throttle cable pulls the throttle cable bracket to provide acceleration, while the other cable helps to push the bracket back into place. Harley recommends replacing both of these cables should one of them become broken or excessively worn. The length of time to complete this replacement should be between 45 minutes and an hour, depending on your skill level.
Removing the Cable
Remove the two screws securing the handle bar housing with a cross-tip screwdriver. Separate the housing components.
Disconnect the two throttle cable ferrules from the throttle grip. Pull the cables out of the housing.
Pull both throttle cables out of the throttle bracket on the carburetor. Withdraw the cables from the engine area, observing their correct installation position as you do so.
Installing the Cable
Insert two new throttle cables into correct position through the engine area.
Connect the two cables to the throttle cable bracket on the carburetor. On the opposite ends, insert both cables through the handlebar housing. Insert the metallic ferrules into the ends of the cables and connect them to the throttle.
Reconnect the housing components together and secure with their screws.
Adjust the throttle cable adjuster nut with a wrench with the throttle wide open, making sure the throttle cam touches the cam stop. Release the throttle.
Adjust the idle cable adjuster nut with a wrench, making sure the cable housing touches the spring located on the throttle cable bracket of the carburetor.
- "Softail Service Manual"; Harley-Davidson; 1997
- Dan's Motorcycle Repair: Bowden Control Cables
Things You'll Need
- Cross-tip screwdriver
- New throttle cables
- SAE wrench set
Jim Murkot Sr. is a respiratory therapist with more than 20 years of hospital management. Murkot began writing professionally in 1993 and has written numerous hospital protocols designed to guide personnel in everything from hospital ethics to emergency response. His work has appeared in eHow as well as in multiple hospitals within the Houston area. He attended Kingwood College and Boston University.