Page 1 INSTRUCTION SUPPLEMENT FOR 1987- LATER YAMAHA YFM350 WARRIOR Removing stock carburetor and cables. Step 3: Remove the carb end assembly and throttle cable adjuster from the engine end of the new Lokar Throttle Cable. 3. Loosen the nut that secures the manual throttle lever so that the lever can move freely. A faulty O-ring will allow air to leak into the carburetor assembly, which will cause the engine to run lean. INSTALLING THE NEW CARBURETOR 5. Remove 3 screws on left (driver) side plate Open the throttle - stick your finger inside to keep it open to slack the cable The cable is held in by a brass retainer in the cam - lift it out and note how it works as you have to put it back later Work the end of the cable out of the cam Cut the stock cable tie from the frame, located above the front cylinder. All this sounds simple – until you have to adapt one to an existing Edelbrock, Rochester Q-jet, or Holley carburetor. Remove the two screws holding the top plate on the carburetor. Pull the OLD cable out of the bulkhead into the engine compartment. ~%¿‚_ɯàWò+ø•ü Then things can get complicated and sloppy. Now adjust the rod or cable until you have some free play. A spring is attached to one leg of the L, and the eye for the throttle cable is on the other leg. Remove the fuel lines from the carburetor. Re-use or get the carb support from backing plate to lifter block. DO NOT REMOVE the ferrule if the cable housing is braided stainless steel! Step 2 5. Remove throttle cable paying close attention to routing, as the new cable… Place Edelbrock carburetor into manifold. Push the new throttle rod into the seat on the trigger. Attach fuel line onto fuel inlet banjo and secure with stock pinch clamp. QQ˜øO¸y�§»yÚ´ÃÑ?Gñ¯©õSןÍÓßíáÙćÛ8~ø‹ïg“˜õÚ´şŒ~ÔãÏúâM¼”½ìÛp¿›ï/¡æ{Åû}ô&[æ)aš¡õ×±nüT÷gIø­MQ…ß:ò}ûß}MXv<5ÿê)*Ò2,N‘pm×a^}ÏWa�%ËAµ@¿R¿B¯¨—õoÔoĞ[jøf;ê4÷CĞÜ/Q‘s¯{å)u Fig. Remove engine cover and tunnel (center of floor board). Install the opposite ends of the throttle cables to the carburetor or throttle body, tightening the threaded ends of the cable guides into the cable bracket completely. But we’ve found several elegant solutions. 2. ë,_o «uqq -�Š( ZÅâ–HKËÀ$:ÀÎ@vPÌÀ Ì ÀÊäÁø�Á˜I�qƒƒS1ÓYæ,!ÌǘW1f1Ú1ÌeÒbdac`´beÔ`”aøÍp…É�é7ç+�6Îkl'¹8yØ_±Ÿáß.tŠS�‰™çÏk ” “ (Éó’ç5k­@,³ ó& ~v.ÓóR�ÜÄÎÀ™¤�x-@€ õGO¶ endstream endobj 9 0 obj <>>> endobj 10 0 obj <>/ExtGState<>/Font<>/ProcSet[/PDF/Text/ImageB]/Properties<>>>/XObject<>>>/Rotate 0/TrimBox[0.0 0.0 612.0 792.0]/Type/Page>> endobj 11 0 obj <>stream Remove throttle cable from throttle pedal and chassis. Throttle Linkage adjustments (cable or rod): While holding the choke plates open turn the throttle linkage by hand to release the fast idle cam from the screw then release the throttle lever. Throttle Cable Installation Step 1: Install throttle pedal in desired location. Remove the two screws holding the top plate on the carburetor. I also installed new bars and a 1" raiser at the same time I installed the Mikuni, so I think the combo may have made the cables a little too short for my application.Took a ton of elbow grease and a few choice words to get the cables seated in the throttle assembly. 5. Remove the black piece covering the brass fitting at the top of the carburetor. Slide the black piece you removed in step 1 over the small end of the throttle cable end and move it up onto the black portion of the cable. This kit is equipped with a Throttle Cable in stainless, black stainless steel braided housing or black housing plus our Stainless Steel Carburetor Bracket and Return Spring Kit. Insert the curved pin at one end of the cable through the eye on the engine throttle assembly. H‰\”ÉŠÛ@E÷úŠZv/M¯^µA. Figure 2 B. Connect the throttle cables to the carburetor bell crank by first installing the closing cable, then the opening cable (Figure 3). Upon successful cable routing, begin the reassembly process. Use masking tape and a felt pen to mark all vacuum hoses connected to the carburetor, including the throttle positioner diaphragm (if so equipped), or vacuum advance line. 8. Install the carburetor. Step 2: Mount Firewall fitting in line with hole in clevis on throttle, or with hole in factory-type pedal. Remove the throttle cable from the carburetor. 11. Disconnect the throttle cable from the throttle body (on the carburetor). Step 17 Go back to the carburetor and disconnect the NEW throttle cable … Step 3: Reconnect the throttle cable to the retaining bracket. This carburetor requires a different style throttle cable than is normally found on a stock buggy. Insert the cable end into the aluminum slide piece and hook it into the small circular groove. I installed the cables on the carb first, and struggled with the throttle install BIG time. Remove the black piece covering the brass fitting at the top of the carburetor. Loosen the nut securing the throttle cable assembly to the carburetor. Compress the spring to allow the cable end to extend through the plastic piece at the end of the spring. ... Any tricks I should know about. 7. 9. Because it is made of rubber, the O-ring will eventually harden and crack. Step 8 Insert the cable you just cut into the adjustable end piece as far as possible and then lock it down with the Step 2: Hook the new cable up to the accelerator pedal. Fuel line may need to be trimmed to proper length. Clean the carburetor mounting surface on both the intake manifold and the carburetor, and place a new carburetor base gasket (not included) onto the intake manifold. How do I install new throttle cables on a 1979 Honda CBX. Screw the cable adjuster on the carburetor all the way in on the carburetor, where the cable attaches to the carburetor. Re-install TM40 choke cable Bolt choke knob bracket to the top forward starter drive cover bolt. şçJ¨±WI�ÖTä¬P[Ñ?h¸Gg¡õÂÂ|õus›¦ĞÒËgdéetq×û¯/Í8Œ&TáŠ> W÷ endstream endobj 12 0 obj <> endobj 13 0 obj <> endobj 14 0 obj <>stream Then pull the cable through all the way up to the threaded stud. Step 2:Place the Throttle Cable Bracket on top of the new carburetor base gasket, with the upper and lower tabs on the left. This device converts throttle movement into voltage that can be easily monitored by the transmission as throttle position. Move the master control lever back to the "STOP" position. 2. Use a quality gas filter before the carb inlet. Step 3: Install throttle cable bracket on carb and then install cable … Reattach the handle molding cover. Screw it on, so that there is slack in the cable clockwise. 4. Make sure fuel petcock is in “off” position. Swap the original PUSH throttle cable to the PULL throttle cable. Disconnect the negative battery cable with an end wrench. Wow, timely post! On the Stock Carburetor Remove the Air-Cleaner assembly so you can see the Throttle Control Mechanism. Unscrew and remove the carburetor assembly from the throttle cable. Attach the top plate and tighten the screws. (Note: In the images in this tutorial, we have replaced the philips-head screws with socket head screws for easier access and removal. Be careful to not tear the gasket between the carburetor body and top plate. Release your grip on the spring and allow the spring and plastic piece to lock the cable in place inside the slide. Then insert the whole slide/spring/cable/top plate assembly into the carburetor. Duo-Pak only available for carbureted applications with Holley, Edelbrock, AFB, Quadrajet and In-Line Dual Quad carbs. Insert the small end of the throttle cable through the brass fitting in the top plate. Entire article contents copyright 2009 Buggy Parts NW, How to Install the BPNW Intake Riser on the GY6 150cc Motor, How to Adjust the Valves on GY6 150cc Motors, You can purchase these screws for your carburetor here. Images 4 & 5: Remove spring and slide assembly. Turn the cable adjusters on the throttle grip housing all the way in, then turn each of them one turn out. As he did so the detent cable … The throttle assembly is be located by identifying an L-shaped lever bolted to the engine housing. Re-route the cables under the frame (Figure 2). Start by installing the cable ends into the throttle body/carburetor and throttle cable housing. Thread the cable into the Wire Stop connector on the engine. Philips Screwdriver or metric Allen wrench. 2. ~%¿‚_ɯàWò+ø•ü Re-install any covers you removed to gain access to the carburetor. The smaller hole on the upper tab is for attaching a kickdown mounting bracket if needed. Step 1: Push the new cable through the firewall. Throttle Cable will be installed into the larger of the two holes in the upper tab of the Lokar Throttle Cable Bracket. Remove seat and gas tank. FIX TRIX: It is advisable to clamp the fuel lines prior to removal. You can purchase these screws for your carburetor here.). This guide will instruct you on how to install a throttle cable into a Koso slide carburetor. I have already removed the old ones but for the life of me I can't decide what has to be done to connect them to the carburetors. and fasten the end of the conduit with the bracket. Unscrew the wing nut on the air cleaner lid and remove the air cleaner housing. Page 2 4. 1. Install threaded stud onto the carburetor bracket. Slide the new cable through the slotted hole in the accelerator pedal. 1. Gently remove the top plate and lift out spring and slide assembly. How to Install a Throttle Cable into a Koso Slide Carburetor. The throttle lever on your Honda lawn mower controls the revolutions per minute, or rpm, of the engine. Some models may use sheet metal clips; if so, remove the cables from the clip. The throttle lever is connected to a cable that runs to your carburetor. Install the throttle cable into the trigger, then re-install the spring and reposition the trigger on the mounting pin. Image 3: Remove two screws from top... 2. Pull the inner wire out of the cable housing. Push the new cable through the firewall and into the engine compartment. 3. Note that the Throttle Cable is attached to the small hole in the carburetor throttle arm, not the large hole with the bushings. H‰\”Ín£0…÷)‹ùѤó œRˆ�E޾>œ¨•&ñ±ğ=şøo÷»}ßÍ&ş= ÍÁÏæÔõíä¯Ãmj¼9ús×GifÚ®™³å¿¹Ôc‡âÃı:û˾? The throttle O-ring forms a seal between the throttle rotor and the throttle body. Tighten the nut that holds the choke knob to the bracket Attach … Sometimes this cable needs adjustment in order for you to have maximum engine efficiency. Locate the conduit bracket on the engine. 3. Push the throttle interlock lever back down. How to Install a Throttle Cable into a Koso Slide Carburetor 1. You can purchase the correct throttle cable for the Koso carburetor from Buggy Parts NW by clicking this link. 6. Diameter of hole in firewall should be 5/16". Make sure the throttle cable is seated properly inside the handle and rejoin the two halves of the handle back together. Retract the throttle arm slightly to create slack in the throttle cable; remove the cable from the carburetor assembly. 4. I have the gas tank off, radiator hoses out of the way. Slide the cables' barrels into the valve catches and twist the throttle tube slightly to check that the valves open and close properly. �QgĞ9uí¨4Ùr°ådËÁ–“-›¥§…§¥§…§µÔš��–��V©š�vñdF‹Œ–-2Zf´Èh™Ñ"£cF‡Œ��¹r9ò8ğ8ò8ğ8280³²}>B��ĞGà#ôøˆ<7aÆåȆzÍ÷+x¿Âì˹fd—Ç™Bvyœ'dWfWdWò+ø•ü After the install was completed Bob made the one and only TV cable adjustment by twisting the throttle to wide open and back a couple of times. Remove choke cable from dash. 10. 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