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New Throttle Assembly, But Cable Too Short!

Discussion in 'The Garage' started by muskallunge, Jul 11, 2017.

  1. muskallunge

    muskallunge XS650 Enthusiast

    Just to make sure I'm not losing my mind, I wanted to get a second opinion.

    I almost done with my first ever build so I'm a green horn. I have a '78 xs650 with bs38 Mikuni Carbs. I purchased a new throttle assembly from TC Bros. with the vintage grips. Bars are not taller so the stock throttle cable should fit, but when I assemble the cable into the grip assembly, the length is too short going into the throttle adjustment by the carbs! I've tried everything I can think of but no bueno. The throttle is way to open and doesn't sit on the throttle adjustment screw.

    Any advise?
  2. Jaydela180

    Jaydela180 XS650 Addict

    Are you sure cable is routed in assembly correctly?

    If you are looking at end of grip, cable should wrap counter clockwise through outer hole to ferrule notch. It could possibly be routed clockwise to ferrule notch, taking up extra inch or so.

    Just a guess here. Good luck
  3. Jaydela180

    Jaydela180 XS650 Addict

    I may have that backwards, now looking at my biltwell whiskey throttle.... but you get my drift.

    In theory, if cable is installed/routed wrong way... It could take up the slack that youre missing.
  4. fredintoon

    fredintoon Fred Hill, S'toon. Top Contributor

    Hi muskallunge,
    if you'd connected the throttle cable backwards it'd work backward too, eh?
    So it ain't that.
    Note that the stock throttle cable's twistgrip end has a short rigid curved end to it's outer cover that attaches to the stock twistgrip with a threaded screw.
    Most likely your aftermarket twistgrip needs a different length of inner cable and attaches the outer cable in a different way.
    I'd suggest that if you still have the stock twistgrip, put it back on.
    Unless the "vintage grip" is glued onto the TC Bros twistgrip it can be moved onto your stock twistgrip.
  5. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Unless the throttle cable and such were made specifically for your bike, bars, and carbs, consider it as a "kit", requiring oldschool cable-making skills. Do a forum search on "throttle cable", with "titles only" checked. Also, check this:

    Hitndahedfred likes this.
  6. muskallunge

    muskallunge XS650 Enthusiast

    It's a "universal fit" and is suppose to work well with x650's. I emailed TC Bros. and they told me to remove the adjustment nut that goes into the bottom of the throttle assembly to give me the extra length and they we're right. Leaves little room for adjustment but now the throttle sits on the adjustment screw on on the carb. Thanks for the responses. Hope this helps someone in the future.
    Hitndahedfred and TwoManyXS1Bs like this.
  7. Jaydela180

    Jaydela180 XS650 Addict

    I agree with twomany on cable are made to fit specific applications, but i did run that tcbros throttle with a stock cable to bs34s without issue.
    Im sure there are differences in a your 78 cable and 38s to my 80 cable and 34s, but in my case it worked fine.
  8. Jaydela180

    Jaydela180 XS650 Addict

    Now that you say that, i do remember removing that nut as well. Glad issue is resolved.
  9. Hitndahedfred

    Hitndahedfred Do I look like a people person to you?

    I have fabbed MANY throttle cables. It is actually pretty easy. Best part is that if you mess up,,, head to a local bicycle shop.
    You can get inner cables with one small end (carb side) in a 6 foot length for like 3 bucks.
    Then you can solder up a larger end for the throttle side or get all fancy and use small tubing with a hole drilled for the cable and fill with solder.
    There are several ways to get it done.
    lakeview and TwoManyXS1Bs like this.

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