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Discussion Starter #1
I replaced the worn out throttle cables on my girlfriend's CM400T with direct replacements from Motion Pro. I routed them the same way the old ones come off but if I try to tuck them under the gas tank or anywhere near the frame they bind. Also steering left to right they will bind. I'm pretty sure they are routed incorrectly. I have them going from the handlebar, turned maybe 30 degrees out toward the headlight, then over the headlight bracket, behind the light, back toward the carbs above the lower triple clamp. Routed like this they stick way out past the tank just looking to catch on something. My clymer manual only says to route them the same as the originals, which in this case they were binding so I replaced them. My guess is that I shouldn't go behind the headlight at all and just go behind the forks near the horn mount and around to the carbs.



Long story short does anyone have a good description or pictures of how to route the cables?
 

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bryantjt said:
I replaced the worn out throttle cables on my girlfriend's CM400T with direct replacements from Motion Pro. I routed them the same way the old ones come off but if I try to tuck them under the gas tank or anywhere near the frame they bind. Also steering left to right they will bind. I'm pretty sure they are routed incorrectly. I have them going from the handlebar, turned maybe 30 degrees out toward the headlight, then over the headlight bracket, behind the light, back toward the carbs above the lower triple clamp. Routed like this they stick way out past the tank just looking to catch on something. My clymer manual only says to route them the same as the originals, which in this case they were binding so I replaced them. My guess is that I shouldn't go behind the headlight at all and just go behind the forks near the horn mount and around to the carbs.



Long story short does anyone have a good description or pictures of how to route the cables?
I'm looking at the diagram in the factory manual right now - sorry no scanner or camera today.

Over the headlight bracket, behind the headlight, over the wiring harness, through a clip just in front of the CDI unit, the clip is long enough to hold the cables below the CDI unit.

(just below the wiring harness the choke cable goes over the top of [on the outside of] the throttle cables and through a clip above the CDI unit)

After the throttle cables go under the CDI they go over the first band around the frame backbone and through the second, then through the middle of the two side plates on the top motor mount and to the carbs from there.

Just a thought here - are you sure its the cables and not the throttle shafts in the carbs that are sticking. I only ask because that was happening to me and I thought it was in the cables at first.

Ernie
 

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Discussion Starter #4
I'll have to mess with it some more, it seems like the cables are too long though. I'm sure it's the cables because it only binds when I steer to either direction, or if I try to tuck the cables up under the gas tank. I did use some cable lube on them as well but it didn't make much difference. The throttle assembly was also removed and cleaned so both ends of the cable are free to move as they should, they just bind up when the cables are flexed in ways they don't want to be, I just can't see how it should go, they seem like a good 4" too long.
 

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Discussion Starter #6
Not yet, crummy weather today. I figured they were the same though given that they had the odd connectors on the end. I'm used to just having threads on each end not these with the bent pipe.
 

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That would be my guess, but I can't say with 100% certainty........
 

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Discussion Starter #10
Went out and ran a wire along the proposed cable route and just as you said the oem length cables were 3-4" longer than the proposed route.


Anyone else not getting the email notifications when there is a reply to a post?
 

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I have superbike bars on my cm400t, but I'm using the original cables. I've positioned my cables so that they loop out just behind the turn signals before heading back in throught the clip under the gas tank. I've never had issues with binding or anything, but maybe it doesn't look as neat. In other words, you don't have to get new cables if you have non oem handlebars, just play around with the routing until you find something that works. /too poor to buy 14$ cables...


edit: oh....sorry, just noticed the date on the last post :/
 
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