How do I reconnect the return throttle cable??

[rfulcher]

This is definately a Murphy's law thing.

While lubing the cables today the return throttle cable disconnected from the bellcrank. I can't even see where it connected. Can't even find a picture of the bellcrank at Ron Ayers or the Yamaha Part site. Don't really have a clue, hope I don't have to take the injector rack off.

Any hints?

 

[mcatrophy]

QUOTE (rfulcher @ Aug 31 2008, 03:55 PM) <{POST_SNAPBACK}>

This is definately a Murphy's law thing.

While lubing the cables today the return throttle cable disconnected from the bellcrank. I can't even see where it connected. Can't even find a picture of the bellcrank at Ron Ayers or the Yamaha Part site. Don't really have a clue, hope I don't have to take the injector rack off.

Any hints?

Don't know if any of these photos might help?

 

[ngarider]

It's a pretty good sized mother***** if it came off.

You'll probably need another set of hands, a bright light, a couple of screwdrivers (long, skinny,flat). Open the throttle, and set one of the screwdrivers to keep it open (on one of the other throttle bodies).

Look at the pulley, you should be able to see the hole and slit in the metal where the barrel fits. The cable slips through the slit which allows the barrel to fit in.

Note the other cable, same thing, just a different position and direction winding (open vs. closing the throttle).

 

[madmike2]

It's a pretty good sized mother***** if it came off.

Yep!

A large pair of forceps might be a helpful tool.....And you'll need to "loosen" the cable adjustment so that you have plenty of slack to play with.

Don't get frustrated if it takes multiple times to get it re-installed. Just walk away and have a glass of tea then come back and try again.

This isn't something that should "accidently" happen....

 

[rfulcher]

It's a pretty good sized mother***** if it came off.

Yep!

This isn't something that should "accidently" happen....

Yea, go figure. If I pushed the return cable as I was lubing at the handlebars and...WTF. Couldn't do that on purpose in a million years.

 

[Capt. Bob]

See,

I told ya we like working on our motorcycles!

clicky

 

[Jon]

While installing the MCC cruise control I also accidentally disconnected the return throttle cable from the bell crank. Luckily, the MCC kit came with two thin, long pieces of flexible steel used to install throttle cables. They have a slit in the end that will hold the cable near its end. I used it to hold the cable and install in back on the bell crank.

You do have to loosen the cable as much as possible and rotate and hold the bell crank all the way on. It's a mother, but it can be done.

 

[timalan]

I did it also when installing my cruise... You need tiny fingers... years of Aircraft Instrument repair experience, The correct vocabulary, and you have to hold your tongue exactly right.

 

[lnewlf]

Took me over an hour to get that wench back on-get as much slack as you can by backing off the adjuster up by the throttle..Made up a few new words while doing this and put a dent in my truck when I threw a tool..

 

[rfulcher]

Got it!

Had to disconnect the cable at both ends and remove the bar that connects all of the ?intake tubes? This cross brace has about 8 screws holding it in place. The cable I was talking about is the return cable. Twisting the throttle moves the connection bell crank down and out of sight. I had to remove the metal cross brace, move the bike into full sunlight, and use an inspection mirror to even find where it connects. I used big curved forceps and a butter knife. The thing that helped the most was the bright sunlight and moving the cross bar so that I could actually see what I was doing.

Took about 90 minutes.

 

[madmike2]

Ahhhh, Grasshopper, you have proved your diligence and have succeeded in overcoming the obstacle to your riding pleasure. B)

:clapping: Well done, sir! :clapping:

"Never give up! Never...never...never...never..never give up." Winston Churchill

Now, twll us, how many glasses of tea did it take to complete the job?

 

[rfulcher]

Ahhhh, Grasshopper, you have proved your diligence and have succeeded in overcoming the obstacle to your riding pleasure. B)
:clapping: Well done, sir! :clapping:

"Never give up! Never...never...never...never..never give up." Winston Churchill

Now, twll us, how many glasses of tea did it take to complete the job?

Live and learn.

I forgot to stop for fluids. Took a couple of quarts of water to rehydrate after I was done. It was hot in the direct sunlight.

 

[CHRIS_D]

It's a pretty good sized mother***** if it came off.

Yep!

A large pair of forceps might be a helpful tool.....And you'll need to "loosen" the cable adjustment so that you have plenty of slack to play with.

Don't get frustrated if it takes multiple times to get it re-installed. Just walk away and have a glass of tea shot of JD then come back and try again.

This isn't something that should "accidently" happen....

I'm sorry I had to correct this!!!!

 

[madmike2]

Don't get frustrated if it takes multiple times to get it re-installed. Just walk away and have a glass of tea shot of JD then come back and try again.

I'm sorry I had to correct this!!!!

Au contrere, mon ami! That will simply add to the frustration level and lead to other problems....or it will lead to "just walking away in disgust". The strongest stuff I drink is tea of soda, but for those who choose to enjoy "adult beverages", that should wait until the job is finished and then one can celebrate their accomplishment.

 

[Rob R]

rfulcher: I just lubed my throttle cables. When reconnected my return spring is inop. Does the return cable just come off the bellcrank below when cable has slack? I though dripping oil into the cable sleeves would have been a 5 min. job.

Rob

 

[rfulcher]

rfulcher: I just lubed my throttle cables. When reconnected my return spring is inop. Does the return cable just come off the bellcrank below when cable has slack? I though dripping oil into the cable sleeves would have been a 5 min. job.
Rob

...would have been a 5 minute job. Thats what I thought also.

Mine came off as I was pushing the return cable in and out to see how much drag was in the cable. My guess is that the extra cable at the bell crank when you push the return cable in causes enough spring tension to pop the cable barrel off of the bell crank.

The hardest part for me was just finding where the return cable connected to the bell crank.

 

[Rob R]

I am still working on reattaching the swagged barrel from return throttle cable onto bellcrank. With very small mirror I can slightly view but with no access. When I tried to remove the cross bar - with the 8 screws, two screws were so tight (locktite) ? that they totally stripped out. Having correct drill bit size and using e-z out I can remove the bar/replace with new screws. I still am shopping for the right tool to grab that barrel and insert. Offset needle nose pliers still won't fit nor can find forcepts as mentioned in previous threads. Any other advice would be great.

Rob

 

[rfulcher]

I am still working on reattaching the swagged barrel from return throttle cable onto bellcrank. With very small mirror I can slightly view but with no access. When I tried to remove the cross bar - with the 8 screws, two screws were so tight (locktite) ? that they totally stripped out. Having correct drill bit size and using e-z out I can remove the bar/replace with new screws. I still am shopping for the right tool to grab that barrel and insert. Offset needle nose pliers still won't fit nor can find forcepts as mentioned in previous threads. Any other advice would be great.
Rob

I could not see what to do until I removed the cross bar I had to use an old school impact wrench, the kind you hit with a hammer, to loosen the difficult screws.

Direct sunlight on a bright day or a lot of light

Big curved forceps. I got mine from Harbor Freight. They are at least a foot long.

A butter knife or something similar to hold the barrel in place when you are "half way there" and have to maneuver the cable wire thru the slot.

I had to use an inspection mirror to find where the cable attached but once I knew where to look I did not need the mirror.

 

[Bull]

I'm never, ever going to touch/lub/or even speak to my throttle cables.

ever.