How do I remove throttle cable on 2002 dyna super glide
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.
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