Question about 2004 Harley Davidson FLHR - FLHRI Road King

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How to install a throttle cable and idle cable

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First remove the air filter cover, air filter, and air filter backing plate. Loosen the locknut on each cable adjuster and turn it nwards making it as short as possible and getting as much freeplay in the cables as possible. Remove the two bolts that hold the right handlebar switch housing together. Lift the top half and disconnect the cables from the throttle sleeve. Remove the throttle sleeve from the handlebar. The the brass ferrel off the ends of each cable and then work the cable out ot the lower half of the switch housing. Sometimes this isn't easy, just use some penetrating oil and keep working with it.

At the carb, lift up on the throttle cable housing and slide the cable through the slots on the throttle cable stop. Rotate the cable around and remove the end from the carb actuator knob. Do the same with the idle cable except that it's got a small spring in the throttle cable stop that you'll probably have to use a small pick to lift it out with.

Installation is the reverse of taking them off. Make sure our put grease on the handlebar and inside the throttle sleeve. When you put it all back together, do not slide it too far up on the handlebar. The inside of the sleeve will rub the end of the handlebar and return like it should. Adjust the cable but leave just a bit of freeplay in each one. Make sure the throttle works properly before you ride the bike.

Good Luck
Steve

Posted on Mar 11, 2011

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1 Answer

How do I remove throttle cable on 2002 dyna super glide


REMOVAL
Loosen the cable adjuster jam nuts, screw the throttle cable adjuster until it is as short as possible, remove the two screws that hold the handlebar housing together to separate the upper and lower housings, unhook the ferrules and cables from the throttle grip and lower housing, remove the air cleaner assembly and disconnect the throttle cables from the carburetor, pull the cable from the housing by placing a drop of oil on the retaining ring that holds the cable in the housing, then firmly pull the bent tubing portion of the cable out of the housing using a rocking motion. The cables can be removed from the carburetor by pulling the outer housing away from plate above the throttle wheel and then with slack in the inner cable twisting the inner cable to allow the swaged end to release from the slot in the throttle wheel and then pull the inner cable out through the mounting plate hole.

If you will reuse the cable wash all components in non-flammable cleaning solvent, carefully blow all parts dry with low pressure compressed air, replace the control cables if frayed, kinked or bent, put one or two drops of oil into the housing of each control cable.

INSTALLATION
Apply a light coating of graphite to the handlebar and to the inside surface of the housings, attach the control cable assemblies to the lower housing, push the silver insert of the throttle cable housing into the hole in front of the tension adjuster screw, push the gold insert of the idle cable housing into the hole at the rear of the tension adjuster screw, install the adjusting screw, spring and friction pad in the lower housing if they were removed, position the throttle grip on the handlebar, place the lower housing on/over the throttle grip, position the ferrules and retaining rings over the cable balls and seat them in the throttle notches, fasten the upper housing to the lower housing using two screws tightened to 35-45 in-lbs (4.0-5.1 Nm), CHECK the throttle cable routing, on FXD, FXDL and FXDX models, the throttle cables are routed between the headlamp bracket and the front fork upper bracket and then under right side of tank to carburetor. On FXDXT models the throttle cables are routed through a wire form that is mounted on the upper fork bracket. On FXDWG models, the throttle cables are routed behind the front fork upper bracket, then under the right side of the fuel tank to the carburetor, install the throttle cables on the carburetor and adjust them at the handlebars and re-install the air cleaner. The throttle cables must be clear of steering stops and not be so tight that the idle speed will be changed when turned from steering stop to steering stop.

Throttle Cable Adjustment
To adjust the throttle cables turn the cable adjusters and jamnuts as short as they will go so that both cables will have zero adjustment at the start of the adjustment procedure. THEN with the front wheel pointing straight ahead turn the throttle grip wide open and hold it there, turn the throttle cable adjuster to lengthen the sleeve until the throttle cam just touches the cam stop. THEN tighten the adjuster jamnut and release the throttle. THEN turn the front wheel full right and turn the idle cable adjuster to lengthen the sleeve until the cable housing just touches the spring in the cable support sleeve. THEN recheck the adjustment by working the throttle grip to be sure the cable returns to idle position when released. If the cable does not return to idle, turn idle adjuster to shorten the sleeve until the correct adjustment is reached and then tighten the jamnut. The throttle control must operate freely without binding.

Oct 02, 2014 | 2006 Harley Davidson FXDI Dyna Super Glide

1 Answer

How do i replace grips on 2009 electra glide ultra classic


For twist grip equipped motorcycles to remove the throttle or right side grip remove the upper and lower switch housing screws, loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw with flat washer, separate the upper and lower switch housings and remove the throttle grip from the end of the handlebar. (To remove the throttle grip, a slight tug may be necessary to release index pins in grip from receptacle in seal cap of twist
grip sensor.)

With throttle cables, to remove the throttle or right side grip slide the rubber boot off of each cable adjuster, loosen the jam nut on each adjuster, turn the adjusters in the direction that will shorten the cable housings to their minimum lengths. THEN remove the two screws and separate the upper housing from the lower housing, unhook the ferrules and cables from the throttle control grip and the lower housing, (remove friction spring, throttle friction screw and spring from the lower housing only if necessary), (only if and as necessary mark the position of the master cylinder assembly forward position and split line on the handle bars) (to be safe squeeze the front brake lever and place a 5-32 inch thick cardboard insert between brake lever and lever bracket and then release brake lever to hold the lever in this place to protect the brake switch from damage if the switch housing and the master cylinder get separated) (and only if and as necessary, loosen the two perch screws) move the lower switch housing as necessary and remove the grip.

To install the throttle grip apply a light coating of graphite to the handlebar and the inside surface of the upper and lower housings, (if removed, install the spring, throttle friction screw and friction spring in the lower housing) (and, if removed, attach the cable assemblies to the lower housing), (throttle control cable has a 5-16 inch fitting end and is positioned to the front of the lower housing. and the idle control cable has a 1-4 inch fitting end and is positioned to rear of lower housing. Install the throttle control grip over the end of the right handlebar, position the lower housing onto the right handlebar, engaging the lower housing with the throttle control grip, position the ferrules over the cable ball ends, seat the ferrules (with the cables attached) into their respective notches of the throttle control grip, install the upper housing over the right side handlebar and secure it to the lower housing with the appropriate two screws and hand tighten them, then align the brake master cylinder and perch assembly with the marks made prior to loosening them, and beginning with top screw, tighten the two screws to 108-132 inch lbs using a T27 TORX drive head and then tighten the upper and lower housing screws to 35-45 inch lbs. THEN point the front wheel straight ahead and WITH THE ENGINE OFF, adjust the throttle and idle cables by turning the adjuster in the direction that will lengthen the cables. Gently twist the throttle control grip to the fully open throttle position (fully counterclockwise) and hold it in this position and turn the throttle control cable adjuster counterclockwise until the throttle cam on the induction module (or carb) contacts the throttle cam stop, release the throttle control grip and turn the adjuster counterclockwise an additional 1-2 to 1 turn and tighten the jam nut on the throttle control cable adjuster. THEN turn the handlebars fully to the right and turn the adjuster on the idle control cable counterclockwise to lengthen the sleeve until the end of the cable housing just touches the spring within the cable guide. NOW check the adjustment by, with the throttle friction screw loosened, twisting and releasing the throttle control grip two or three times. The induction module throttle wheel must return to the idle position each time the throttle grip is released. If the throttle does not return to idle, turn the idle adjuster, shortening the cable sleeve until the correct adjustment is obtained, tighten the jam nut and slide the rubber boots over each cable adjuster. NEXT start the engine and with it idling turn the handlebars through their full range of travel and if the engine speed changes at all during this maneuver, adjust the control cables according to the foregoing procedure so that there is no change in the idle speed when the handlebars are rotated through their entire range of travel.


To remove the clutch or left side grip remove the two screws and separate the upper housing from the lower housing. Mark the forward position and clutch perch split line on the handlebars and then as necessary loosen the two clutch perch screws and move it out of the way so that you can access the grip end. If you want to save the grip take a small screwdriver with about an eight inch length and insert it into the grip, wiggling it to loosen the glue somewhat and then spray some brake kleen into the space under the grip where the screwdriver blade is inserted and wiggle and twist the screwdriver around to loosen the rest of the grip glue and pull the grip off. Sand down the handle bar area where the grip will rest and apply grip cement to the area and slip the grip on. If the left hand grip is patterned, align it with the pattern on the right hand grip with the throttle in the fully closed position, immediately push the grip completely onto the end of handlebar using a twisting motion. Do not hesitate when installing the grip or the adhesive may dry before installation is complete. Allow 6 to 8 hours to elapse at 70 degrees F to allow the adhesive to fully cure. If a newer non-glue grip is being installed slip it on with the flats properly oriented to fit with the switch housing halves when they are installed. Install the switch housing halves and lightly tighten the two screws and then orient the clutch perch to the previously made alignment marks and beginning with the top screw, tighten the screws to 108 - 132 inch lbs using a T27 drive head and then tighten the switch housing screws to 35-45 inch lbs.

Sep 20, 2014 | Motorcycles

2 Answers

2003 ford escape -- suddenly the throttle seemed to be sticking, high rpm on start up and while driving. Hit gas peddle a couple of times and then it wouldn't idle normally... almost on the pin. Looked...


Hello,
I don't believe I can help you with the throttle cable comming off the pin without actually being able to see it, but, if you get it hooked back up and still have problems with the idle, the most common cause for that is a faulty TPS, ( throttle position sensor ), sometimes you can remove the throttle body, clean it, and then re-install it. This usually solves the problem.
I hope this helps you.
Donnie

Feb 20, 2011 | 2003 Ford Escape

2 Answers

Where is throttle positioning sensor on a suzuki forenza


Removal & Installation
  1. Disconnect the negative battery cable.
  2. Disconnect the Intake Air Temperature (IAT) sensor connector.
  3. Disconnect the breather hose from the valve cover.
  4. Remove the air intake tube.
  5. Disconnect the throttle cables by opening the throttle and moving the cable through the release slot.
  6. Disconnect the vacuum hoses from the throttle body.
  7. Disconnect the Throttle Position (TP) sensor and the idle air control valve connectors.
  8. Disconnect the coolant hoses from the throttle body.
  9. Remove the throttle body and discard the gasket.
  10. Remove the TP sensor.
  11. Remove the Idle Air Control (IAC) valve.
  12. Remove the throttle body retaining nuts.
  13. Remove the throttle body.

To install:

  1. Install the throttle body.
  2. Connect the TP sensor connector and the IAC valve connector.
  3. Connect the coolant hoses to the throttle body.
  4. Connect the vacuum hoses to the throttle body.
  5. Connect the throttle cable.
  6. Install the air intake tube.
  7. Connect the breather hose to the valve cover.
  8. Connect the IAT sensor connector.
  9. Connect the negative battery cable.
  10. Fill the cooling system
  11. shinehutt_33.gif
  12. i hope this helps tps is attatched to hrottle body on other side than throttle cable
  13. plz dont forget to vote rep[ly if you need more help

Jan 17, 2011 | 2006 Suzuki Forenza

1 Answer

Diagnostics test says idle air control underspeed error? how do i fix 1999 ford explorer


change the idle air control valve.

Idle Air Control (IAC) Valve OPERATION The Idle Air Control (IAC) valve controls the engine idle speed and dashpot functions. The valve is located on the side of the throttle body. This valve allows air, determined by the Powertrain Control Module (PCM) and controlled by a duty cycle signal, to bypass the throttle plate in order to maintain the proper idle speed. Fig. 1: Typical Idle Air Control (IAC) valve which is mounted to the throttle body - cutaway view shows air bypass direction 89684g16.gif
--- REMOVAL & INSTALLATION
  1. Disconnect the negative battery cable. To remove the IAC valve, first disconnect the negative battery cable, then the IAC wire harness plug 89684p03.jpg
    Next, remove the two IAC valve attaching bolts . . . 89684p04.jpg
    . . . and pull the valve from the intake manifold 89684p05.jpg

  2. Disengage the wiring harness connector from the IAC valve.
  3. Remove the two retaining screws, then remove the IAC valve and discard the old gasket. To install: When installing the valve, always discard the old gasket and install it using a new one 89684p06.jpg

  4. Clean the IAC valve mounting surface on the throttle body of old gasket material.
  5. Using a new gasket, position the IAC valve on the throttle body. Install and tighten the retaining screws to 71-106 inch lbs. (8-12 Nm).
  6. Attach the wiring harness connector to the IAC valve.
  7. Connect the negative battery cable.
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Oct 15, 2010 | 1999 Ford Explorer

1 Answer

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

Idling problem toyota altis


Either there is a vacuum leak causing the high idle, or
the IACV is bad or being controlled by the computer to make idle speed too high:

To change the IACV refer to the following:
Idle Speed Control (Idle Air Control) Valve Removal & Installation To Remove:
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Remove the throttle body. Idle speed control valve toy_cor-04-18-1187.gif

  3. Remove the 3 mounting screws from the throttle body. Remove the idle speed control valve and gasket.
To Install:
  1. Using a new gasket install the idle speed control valve on the throttle body with the 3 mounting screws.
    • Tighten 33 inch lbs. (3.7 Nm).
  2. Install the throttle body.
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Jul 16, 2010 | 2004 Toyota Corolla

1 Answer

HOW TO CHANGE THROTTLE / IDLE CABLES ON 2001 FXDXT


To change the throttle cables, remove the air cleaner, filter, and backing plate to allow good access to the carburetor. Some bikes even require removing the fuel tank. Then loosen the throttle cable and idle cable adjusters and turn them to their shortest position giving you as much slack as possible.

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.

With the grip ends loose, removing the carb ends is simple. Get some slack in the cable, align it with the slot in the carb and remove it. Do the same with the idle cable.

Installing the new cables are the exact reverse of removing the old ones. Remember, the idle cable is the one with the spring on the cable. If you purchased any cable other than a Harley cable, lube the cable with some "Dri-Slide". I always lube any cable (including Harley cables) that I install. Lube the inside of the throttle grip and the outside of the handlebar with white lithium grease. Lube the nylon part of the throttle grip with the same grease where the cables connect to it.

Once you get the cables on, it is very important that you get the cables adjusted correctly. Adjust the throttle cable first so that you have just a bit of slack in the cable. The throttle should open wide open and when shut, you should have a bit of slack in the cable. Then I like to adjust the idle cable tight enough so that I actually starts to compress the little spring on the cable at the carb end. Not much but just a bit of compression on the spring.

Once you're finished, make absolutely certain that your throttle control is working smoothly, freely, and will return to closed position when you let go of it. If it won't do this, it is unsafe. Work with it until you find the problem. Failure to do this job properly could cause throttle stickage and lead to serious injury or death. Make SURE you have the job done correctly before riding the bike.

Good Luck
Steve

Jul 12, 2010 | 2001 Harley Davidson FXDXT Dyna Super...

1 Answer

Need to replace a idle air control valve on a 1999 300M Chrysler


Removal & Installation
  1. Disconnect the negative battery cable.
  2. Disconnect the IAC electrical connector.
  3. Remove the IAC mounting screws.
  4. Remove the IAC.



da3669e.gif

To install:
  1. Install the IAC to the throttle body.
  2. Tighten mounting screws to 5.1 Nm (45 inch lbs.) torque.
  3. Attach electrical connector to the IAC.
  4. Connect the negative battery cable.
  1. Disconnect electrical connector from IAC motor.
  2. Disconnect air plenum (where applicable).
  3. Remove two mounting bolts (screws).
  4. Remove IAC motor from throttle body.

3ccd55e.gif

To install:
  1. Install IAC motor to throttle body.
  2. Install and tighten two mounting bolts (screws) to 60 inch lbs. (7 Nm) torque.
  3. Install electrical connector.
  4. Connect air plenum (where applicable).

Mar 06, 2010 | 1999 Chrysler 300M

2 Answers

I am changing the handlebars to 16" ape hangers, need the instrucitons to change the clutch cable and the throtle/idle cables


To change the throttle/idle cables, first you need to remove the fuel tanks so you can get to the carb/throttle body. Loosen the adjusters at the throttle grip on the handlebars. Remove the idle cable first and the remove the throttle cable from the carb/throttle body. Then take the two bolts out of the throttle grip housing halves and carefully seperate them. Remove the old cables from the twist grip. Reinstall new cables in the reverse procedure. Before starting the bike, make absolutely sure that the throttle cables work like they're supposed to and the carb/throttle body will close completely.

To remove the clutch cable, remove exhaust system or whatever might be in the way on the right side of the bike. You need to remove the right side transmission cover. Drain the transmission oil. Remove the chrome right side transmission cover. Disconnect the clutch cable from the clutch release mechanism. Screw the end of the clutch cable out of the cover and take the cable loose from the clutch lever on the handlebars. Reinstall in reverse order making sure you install a new O-ring on the cable at the transmission cover. Replace cover and refill transmission with oil. Reinstall anything else you had to take off.

Feb 15, 2010 | 2008 Harley Davidson FLHR Road king

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