Quick Turn Throttle Mod
Tutorial
Parts Needed:
1" PVC sprinkler pipe coupler (bought mine at OSH)
PVC Cement
Belt Sander
Hack Saw
Grease
First, remove the throttle bolts, and pull apart the housing. The two sides come right off, then unhook the throttle cables and slide off the throttle.
Use a hack saw to cut a slice off the end of your coupler. Mine cost $0.44. Cut it with a bit extra- it's easier to remove material than add it back later!
I used a belt sander to clean up the edge, and sand it down to the right thickness. Check often!
Thickness looks good.
Cut it at one point, then cut it at another to knock out a SMALL portion. Test fir it, and cut off another piece until it fits just right- measure twice, cut ONCE! Mess up and you'll be making another.
I then used 200 grit sandpaper to rough the inside of the PVC piece and the outside of the throttle tube for the glue to work better.
Apply PVC glue to BOTH pieces. Assemble, and hold together in proper position for 30 seconds.
Use a razor blade to scrape off the excess glue. Yes, that is my dried blood on the blade (unrelated incident)
You will then have to grind off the two notches on the bottom piece of the throttle housing to clear your PVC spacer. If it's worth doing, it's worth overdoing- I used a 1/4" mill bit.
There it is- I love milled cuts.. so clean :)
Test fit to make sure your throttle spins freely
Grease up your throttle cable areas. I also filed a small groove for the cable, which is probably unnecessary (Stock tube is smooth). And I filed a bevel at each end to ease the cable transition over the PVC part.
Loosen your throttle cable adjuster all the way- it's behind the headlight- slide off the rubber boot to expose. And reassemble, then adjust your cable tension. Mine was just right with the adjuster maxed out loose!
Here is the difference between the idle and WOT positions. I should have measured the stock positions, but either way, there is a felt difference. There shouldn't be as much hand switching to grab full throttle anymore!!