Question about 1999 kawasaki EN 500 Vulcan Classic

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Throttle cable very little movement in hand grip but isn't bindin

When going to open throttle, lines don't look kinked, but not opening carb more than quarter inch. Handle grip only turns about quarter inch as well. Bike has sat 5 years in garage under cover. Changed all fluids and installed new battery but when going to crank over, throttle won't open up.

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  • David Kunz May 05, 2010

    Disconnected both cables at the throttle grip and also the decelerator cable at the carb. Now I can freely move the linkage at the carb using the accelerator cable, but the decelerator cable appers to be bound up. Shot some WD40 down both cables and hopefully maybe by morning the stuck one might be loose. If not I will most likely have to replace the cable. How much will this cost if I do it myself, and is it hard? Do I need to remove the gas tank to properly route the new cable?



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You need to remove the carbs and they need to be cleaned, what has happened is the gas went bad and it has gummed up the throttle shaft and most likely lots of other parts in the carburators, these sound pretty bad, what needs to be done is they need to be completely disassembled and soaked in a strong solution to free and clean everything up, you are looking at about a $300-400 bill at a shop.

Posted on May 04, 2010

Testimonial: "Very helpful information. Thank you!"

  • Jetskidoc
    Jetskidoc May 05, 2010

    Cables retail about $22 each, I would just replace the cables, if this bike has been sitting also you'll likely need tp clean the carbs



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Remove the two screws that hold the right handlebar switch housing halves together. Carefully seperate the halves and remove the cables from the throttle grip. Do not lose the cable ferrels. The cables should pull out of the bottom of the switch housing now. You may have to put some penetrating oil on the metal ends that are in the switch housing and work them around a bit. They have a little metal ring on them that expands once it's in the hole of the switch houseing. They can be very aggrevating to say the least.

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