Which throttle cable should you use for your new internal throttle?

We receive quite a few calls from customers asking which throttle cable to use when installing our internal throttle. There are two ways to go about this, however only one way is correct and safe.

The INCORRECT way:

More often than not guys try to save a few bucks and re-use the cable that was hooked up to the stock/aftermarket throttle housing. This is not the recommended method and we do not advise this method when installing our internal throttle. In IMAGE #1 below you will notice the stock throttle housing and throttle cables commonly seen on Harley Davidson motorcycles. Numbers 4 and 5 show the push and pull throttle cables. Numbers 6 and 7 show the throttle cable adjuster.

Now keep in mind that many Harleys use push/pull throttles, whereas the internal throttle is a pull only throttle. Employing this method, one would cut the adjuster off on the ‘pull’ cable right where the cable housing meets the adjuster. Once the adjuster is cut off, you now have no way to take out any free play that is in your newly installed internal throttle. Have you ever ridden a bike with a throttle that has gobs of free play? I’ll save you the retort and tell you that it’s awful and translates to a shitty ride and a poorly set-up motorcycle. If you are anything like me, you want all free play to be adjusted out so when you twist the throttle there is absolutely no delay in throttle response. Again, we do not recommend this installation method due to it simply being the wrong way and is unsafe.

The CORRECT way:

The correct way to install you internal throttle is to purchase a throttle cable that is designed to work with internal throttles.These cables have a built-in, in-line adjuster. We offer a cable from Barnett, which happens to be made in the USA, and is designed to be used with internal throttles. You can purchase it in our store by clicking here for just $19.99. You will notice in IMAGE #2 below that an in-line adjuster is located near the carburetor. The adjuster is typically 5”-6” from the carburetor for easy access when adjusting.

These throttle cables are approximately 53” long and are designed to be cut to the desired length during the install. As for the install, one end of the cable will attach to your carburetor (don’t worry, these are universal cables with a variation of ends for many popular carbs) and the opposite end is cut to length, both cable and cable housing. Keep in mind that when you cut the cable, you are only cutting the housing. The cable that operates the carb slide/butterfly is left long and cut later during the internal throttle installation process. Be certain that before you cut anything make sure that the adjuster is collapsed all the way.

Once your new internal throttle is installed and is operating smoothly without any rough spots or sticking, it’s time to adjust out the free play. Simply rotate the adjuster to effectively lengthen the cable housing, which in turn reduces the amount of throttle free play. Make sure you don’t go too far as you will begin opening the carburetor slide/butterfly. I like to adjust with one hand on the adjuster and the other on the throttle until all free play is gone.