Question about 2003 Gas Gas EC 400 FSE Supermotard

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Placement of Throttle Cable

Has anyone else had a problem with burning the throttle cable? I noticed when I purchased my fse400 that the cable was burnt and it got worse after taking it out on the first ride. It was running horizontally out from the throttle body and then between the radiator and the frame. This made it run very close to the pipe where it was coming out of the head. I am getting a new cable and don't want to make the same mistake. It could cause serious problems and strand me out in the bush.

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I can't tell you how glad I am to hear of a problem my '05 FSE doesn't have! Mine won't melt the throttle cable to do that it would have to start (kick or electric) and then stay running (just shuts off now and then). Haven't dared take it more than 1/2 mile from home (couldn't push it back from any further) now it's warm enough that I don't want to push it at all so it will probably continue to gather dust until fall. I sure wish there was a dealer within a few hours ride who knew anything about them.,,

Posted on Nov 10, 2008

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Hard to start. once it starts will not idle, acts as if the throttle is pinned open and runs full bore. When running full throttle on its own the kill switch will not shut the saw off.


Remove the carburetor cover and observe the action of the carburetor throttle arm as you actuate the throttle. If the arm doesn't move, disassemble the throttle trigger assembly (making part placement notes as you do so) and clean out any accumulation of sawdust/dirt. Make sure the cable or rod which connects it to the throttle arm will move--there should be spring return of the throttle arm to idle position. If this fixes the throttle problem, but the kill switch still doesn't work, you may have to remove the left side case to access the ignition module and the kill switch wire which plugs into the end of the module. The switch itself may be full of sawdust as well preventing contact to engine ground. Hope this helps!

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When i turn on heater or fan engine revs over 3000 rpm


Idle Air Control Valve Pintle may be bad If you disconnect the IAC and the problem ceases it can point to this being the problem.: Removal & Installation 3.5L Engine To Remove:
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove the fuel injector sight shield.
  3. Drain the cooling system.
  4. Remove or disconnect the following:
    • The air cleaner intake duct. Figure of IAC and TPS electrical connectors disconnected. aurora_g1.gif

    • The idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Figure of cruise control and throttle control cables removed from throttle lever. aurora_g2.gif

    • The cruise control cable and throttle control cable from the throttle body lever.
    • The fuel pressure regulator vacuum hose, positive crankcase ventilation (PCV) hose and the throttle body vacuum port hose.
    • The throttle body coolant hoses.
    • The throttle control cable bracket, leaving the throttle and cruise cables connected.
    • The upper nut holding the throttle body to the intake manifold.
    • The throttle body assembly.
  5. Clean the gasket mating surfaces.
To Install:
  1. Install a new gasket and new studs if necessary.
  2. Install or connect the following:
    • The throttle body assembly.
    • Start the top nut by hand.
    • The throttle body coolant hoses.
    • Position the throttle control cable bracket and hand start the retaining nuts and bolt.
    • Torque the three throttle body retaining nuts to 89 in.lbs. (10 Nm). And the bracket retaining bolt to 115 in.lbs. (13 Nm).
    • The throttle body vacuum port hose, PCV valve hose and the fuel pressure regulator hose.
    • The throttle control and cruise control cables to the throttle body lever.
    • The IAC valve and TP sensor electrical connectors.
    • The air intake duct.
  3. Refill the cooling system.
  4. Install the fuel injector sight shield.
4.0L Engine To Remove:
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Relieve the fuel system pressure.
  3. Remove or disconnect the following:
    • Negative battery cable.
    • The Mass Air Flow (MAF) sensor electrical connector.
    • The air cleaner intake duct.
    • The PCV valve fresh air tube. Figure of cruise control cable removed from throttle cable bracket. aurora_g3.gif

    • The cruise control cable and throttle control cable from the bracket.
    • The cruise control cable and throttle control cable from throttle body lever. Figure of IAC valve and TPS connectors removed. aurora_g4.gif

    • The idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Figure of fuel lines removed from retainer on throttle cable bracket. aurora_g5.gif

    • The fuel feed and return lines from the retainer on the throttle control cable bracket.
    • The transaxle shift cable clip from the throttle control cable bracket. Figure of throttle body removed from water crossover. aurora_g6.gif

    • The throttle body from the water crossover.
To Install:
NOTE: The Mass Air Flow (MAF) sensor inlet and the outlet of the air cleaner assembly must line up when installed. Misalignment may cause MIL illumination or driveability concerns.
  1. Install or connect the following.
    • The throttle body to the water crossover. Torque the bolts to 106 in.lbs. (12 Nm).
    • The IAC valve and TP sensor electrical connectors.
    • The throttle and cruise control cables to the throttle body lever.
    • The throttle and cruise control cables to the throttle control cable bracket. The transaxle shift cable clip to the throttle control cable bracket.
    • The fuel feed and return line retainer to the throttle control cable bracket.
    • The MAF sensor electrical connector.
    • The air cleaner intake duct clamp. Torque the clamp to 27 in.lbs. (3Nm).
    • The PCV valve fresh air tube.
    • The fuel injector sight shield. Torque the nuts to 20 in.lbs. (2.3 Nm).
  2. Install the negative battery cable.
  3. Pressurize the fuel system and verify no leaks.
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Oct 07, 2010 | 2001 Oldsmobile Alero

1 Answer

Change speed sensor on trans. and still will not


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4 Answers

Engine revs when turning right.


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1 Answer

Mechanical question


That's interesting, I have run throttle cables for many years with minimal stretching. Are you tightening the lock nut at the adjustment? And are you sure you have the cables adjusted properly? Specifically the return cable, if it is too tight it will conflict with the primary cable, this will cause the primary cable to (over time) pull on and eventually stretch the return cable. Try loosening the return cable, then with the throttle wide open ,tighten the return until it has just "a hair" of free play. Then adjust the throttle to where it has just a very small amount of free play ,then tighten the lock nuts. Then check to be sure the return cable has some play when the throttle is closed and if necessary re-adjust.

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1 Answer

Sticking Throttle


Two further possibilities: the cable itself is frayed, or grit and dirt have got in and are preventing the cable from sliding within the lining. If it's either of these cases, I think you'll need a new cable

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