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Post by murphsprin on Jul 15, 2022 16:48:26 GMT -5
I'm trying to set up my cables. I have the angle gauge from rotory recycle but I can only get it to 65 maybe 70deg before it starts to hold the throttle from closing all the way. I can get it to open to the 82 deg called for but then the throttle blade is not closing all the way
Am I missing something?
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Post by wayne on Jul 15, 2022 17:57:53 GMT -5
Possibly. All cable restraints must be loosened. The one to miss is the small grub screw and lock nut under the throttle grip body.
If you haven't done this, it will restrict the range so you'll get exactly what you're noting. Either/Or but not all.
This was introduced early on to pick up the slack on the cables when opening the throttle (a fault noted by early test riders).
Undo the lock nut and wind the grub screw out.
One other thing, even if this turns out to be issue, cable "weight" can prevent the primary butterfly from closing fully. To set the zero position with the throttle grip fully closed, you may have to use a small dowel to gently push the primary closed, set the zero mark and then you won't have to worry about it.
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Post by murphsprin on Jul 15, 2022 18:14:57 GMT -5
All the cables are loosened completely including the screw on the throttle
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Post by murphsprin on Jul 15, 2022 18:26:50 GMT -5
Cables could be a but sticky. I'll try and get some lube in them
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Post by wayne on Jul 15, 2022 20:21:50 GMT -5
Old RE5's have lots of places to stick. Just lubing the cables may not be enough. I've used ceramic grease on the inside of the throttle grip and generously on the plastic turnbuckle parts inside the handlebar casing. The splitters under the tank can also get very sticky, definitely worth cleaning those up if the cable lube doesn't help.
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Post by murphsprin on Jul 15, 2022 21:38:48 GMT -5
Lubed up the cables and started over again and was able to get about 75 deg opening before it stated to hold open on the closed position. But decided to continue on and all the other adjustments where able to be made to spec. Took it our for it's first ride znd it is better than expected. It does have the 4k hesitation but really pretty minor. Going to put some miles on and go try to dial that out
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Post by hudson on Jul 15, 2022 23:27:02 GMT -5
It sounds like you may have an early throttle cable -37000 vs -37001 This number is stamped/printed in white near the grip end adjuster. This is mentioned in service bulletin RE-9. Bulletins are listed under resources then look at the list that has the service manuals. I saw some of these early cables on e-bay recently. Bulletin #9 explains how to work around this small problem. Let us know if this is the case.
Brian
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Post by murphsprin on Jul 17, 2022 13:02:00 GMT -5
It does have the 37001 pull throttle cables. Is there a different return cable as well?
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Post by hudson on Jul 17, 2022 14:11:11 GMT -5
It looks like there has been only one return cable -37600. The next place I would look is inside the handle bar throttle housing to see if the adjustable rotation stop is broken or possibly assembled incorrectly. The plastic stop should be fitted to the groove on top of the adjusting screw.
Brian
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Post by timpa136 on Jul 17, 2022 16:27:59 GMT -5
It sounds like you may have an early throttle cable -37000 vs -37001 This number is stamped/printed in white near the grip end adjuster. This is mentioned in service bulletin RE-9. Bulletins are listed under resources then look at the list that has the service manuals. I saw some of these early cables on e-bay recently. Bulletin #9 explains how to work around this small problem. Let us know if this is the case.
Brian Did you find a stopper in the grip as mentioned? I was told to line out that portion of #9 as if those grips were all removed before delivery. Insure no cable is unseated under the tank or at the metering pump. Tim |
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Post by hudson on Jul 18, 2022 15:10:39 GMT -5
I was referring to the note at the bottom of page 4 continuing to the top of page 5 in bulletin RE9 that speaks to the lack of cable slack in the early throttle cables. Thank you murphsprin for confirming that is not the case in your bike. I think timpa has some likely spots to investigate.
Brian
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Post by murphsprin on Jul 19, 2022 7:13:07 GMT -5
The small set screw on the handle bar adjuster is there and unscrewing it did get me more adjustment still not quite enough but after reading the workaround you mentioned it seems that it won't matter much if it closes all the way as long as it's closed below 18 deg. I will make another go at it today. I also think I may remove the push cables. I'm just reluctant to ruin good cables as I'd probably have to cut then so I can leave the housings in place for appearances.
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Post by hudson on Jul 19, 2022 9:23:34 GMT -5
Check that the plastic stop is attached to the top of the adjusting screw correctly. Other than that I think you are OK to use the 18 deg. at closing to get to wide open.
Brian
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Post by murphsprin on Jul 19, 2022 16:54:16 GMT -5
The bulletin for the throttle cable change also mentions the throttle tube to be replaced any way to tell if that is correct? It now seems like that is the limiting factor. I filed some our of the spot on the tube that contacts the housing at wide open and got some more opening
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Post by hudson on Jul 20, 2022 10:04:21 GMT -5
I think you have chased this all the way to the end , My last thought is that may be an old throttle tube somehow. I believe when the replacements were sent to the dealerships they came with a grip installed so the old one might have laid around until nobody knew what it was, but hey it has a new grip. A new grip and tube was available from suzuki within the last year and may still be. Left grip is now discontinued.
Brian
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