MadKaw wrote:.....You can make them yourself if you can find the right plastic tube size........
I've knocked up a few of these Jeebz, its a piece of piss.
The 'right' plastic size is......the flared end of normal orange plastic electrical conduit ! I *think* its about 20mm diameter (something like that), and the process is really easy....(you can only use the wider flared end, about 30mm at the end of any length of orange conduit/fitting is flared)
Cut a 4mm wide 'strip' off the flared end of the conduit
Tidy up the cut-off section with a small round file
Useing a pair of sidecutter, remove a section of the piece about 8mm long - this may need to be trimmed down a 'tad'. This will give you a 'C' shaped piece of conduit, 4mm wide, with a gap that should be about 8mm wide.
Pull the throttle assembly apart, and with the cables loose and hanging in the breeze, adjust both cables so that you have *maximum* freeplay.
In the throttle housing, there are 2 small rectangular tabs that are part of the casting, on the inside of the bottom piece - these get in the way with the throttle insert (both this style and the ebay one) - the trick to removing these, is to use a small 5mm wide *sharp* chisel - put the housing on a bench, get the chisel in *exactly* the right spot hard against the side of the housing and centred over the small tab.......and one good sharp smack with a hammer (not too hard), will instantly remove the tab. Repeat on the other side of the housing. You can fuck around for hours with a file if you want, this method is short sharp and effective. Don't hit too hard or you may drive the chisel too far into the housing. You may have to use the chisel to remove any remaining trace of the tab, otherwise the throttle could stick.
You then just slip the orange piece of conduit over the stock inner throttle housing - the bit where the cables normally sit. Then refit the cables and upper assembly all together..........
This should result in a throttle that is now about 1/5th turn, that does not bind, and which cost SFA to make.
Hoffy has one of these on his barge, there is one on my barge, and another one on Aussie Ninjas crim (ZX10). Its a real cheap and easy mod, and so far, all 3 inserts have worked without fault.....mine has been on for >12 months now.
The only thing you may find is that you now have *zero* freeplay on the throttle cables - that is what happened with AussieNinja's 10 - as soon as you touch the throttle, it starts to rev. With both barges, there is a poofteenth of play left in the cables.....its no big deal really.
