Throttle Cable Issue

[Chili]

Since changing to a Renthal Mini Hi bar on my sons 99 KX80 I've had some cable issues. The clutch cable was extremely tight even after adjusting it as loose as I could and snapped 5 minutes into the next ride. Solved that issue with a new clutch cable and a slight routing variation even though the original cable was in the stock routing. Now I also noticed whenever I turn the bars all the way to the right the motors starts to rev really fast and returns to normal when I return the bars to center or left of center. I think I have adjusted the cable as loose as I can, I turned the adjusters all the way into the throttle assembly and all the way in at the carb. I assume turning in is loosening as when I turned it out the idle started to rise. I've looked for another routing for the cable but didn't see a better one than the stock routing.

Does anyone have any ideas? I don't imagine it's the cable because if anything the cable would stretch as it ages not shrink. Also should that throttle cable always be at the top of the throttle or could it be positioned at the bottom (i.e. under the brake reservoir instead of above it) as that may give me the slack I need.

Thanks for any help!

 

[biglou]

Can you run the cable behind the bars? On my kTm, the stock routing is that way. Just run it over the top and then down the left side of the tank. Be sure to check it out for any binding or interference with anything else.

 

[KelvinKDX]

Originally posted by Chili
Since changing to a Renthal Mini Hi bar on my sons 99 KX80 I've had some cable issues. The clutch cable was extremely tight .........!

Chili

Did you ever get this solved?  I ran into the same situation this week-end while putting a set of Renthal #757 mini-hi bars on my wifes kx100.

 :confused:

I will hit the local bike shops this evening but they are usually about as helpful as a brick wall when it comes to issues varying from stock.

 

[muddy226]

Pobably better in the long run to get new cables made up, and stick to original routing. I'm in UK so this may not help much but I had some made by Venhill Engineering, Dorking, Surrey, who specialize in cables, hydraulic conversions etc., good stuff not expensive.

 

[KelvinKDX]

Anybody know who makes custom cables in the US?

It looks like i might be able to use a clutch cable off of an older KX125.  The throttle cable is another issue with that PWK28 carb on there.

 

[Chili]

Jim I sent a reply to your e-mail. We didn't end up needing to change the cables but just played with the routing a bit. You also had to watch the position of the throttle housing on the bar to get the maximum amount of slack out of the cable.