Throttle Cable

REMOVAL OF THROTTLE CABLE




1. DISCONNECT THROTTLE CABLE
a. Disconnect the cable housing from the bracket.
b. Disconnect the cable from the throttle linkage.




2. REMOVE NEUTRAL START SWITCH
a. Remove the clips and, disconnect the transmission control cable from manual shift lever.
b. Remove the manual shift lever.
c. Remove the neutral start switch.

3. REMOVE VALVE BODY




4. PULL THROTTLE CABLE OUT OF TRANSMISSION CASE
a. Remove the bolt and retaining plate.
b. Pull the cable out of the transmission case.

INSTALLATION OF THROTTLE CABLE



1. INSTALL CABLE IN TRANSMISSION CASE
a. Be sure to push it in all the way.
b. Install the retaining plate and one bolt.
2. INSTALL VALVE BODY

3. IF THROTTLE CABLE IS NEW, STAKE STOPPER ON INNER CABLE



a. Bend the cable so there is a radius of about 200 mm (7.87 in.).




b. Pull the inner cable lightly until a slight resistance is felt, and hold it.
c. Stake the stopper 0.8 - 1.5 mm (0.031 - 0.059 in.) from the surface of outer cable as shown.




4. CONNECT THROTTLE CABLE
a. Connect the cable to the throttle linkage.
b. Connect the cable housing to the bracket.

5. ADJUST THROTTLE CABLE
a. Depress the accelerator pedal all the way and check that the throttle valve opens fully.
NOTE: If the valve does not open fully, adjust the accelerator link.
b. Fully depress the accelerator.
c. Loosen the adjustment nuts.



d. Adjust the cable housing so that the distance between the end of the boot and stopper on the cable is the standard.

Standard boot and cable stopper distance: 0 - 1 mm (0 - 0.04 in.)

e. Tighten the adjusting nuts.
f. Recheck the adjustments.





6. INSTALL NEUTRAL START SWITCH
a. Install the neutral start switch.
b. Install the manual shift lever.
c. Adjust the neutral start switch.
d. Connect the transmission control cable.