R and r throttle cables - 2001 Harley Davidson FLHR - FLHRCI Road king

throttle cable ??? should actually have a throttle rod that goes to a very short piece of cable. and this cable only goes from the carb to the throttle rod. the cable is actually easy to replace. it's only 3 inches long. the throttle rod or trigger requires removal of one side of the handle.

REMOVAL
Loosen the cable adjuster jam nuts, screw the throttle cable adjuster until it is as short as possible, remove the two screws that hold the handlebar housing together to separate the upper and lower housings, unhook the ferrules and cables from the throttle grip and lower housing, remove the air cleaner assembly and disconnect the throttle cables from the carburetor, pull the cable from the housing by placing a drop of oil on the retaining ring that holds the cable in the housing, then firmly pull the bent tubing portion of the cable out of the housing using a rocking motion. The cables can be removed from the carburetor by pulling the outer housing away from plate above the throttle wheel and then with slack in the inner cable twisting the inner cable to allow the swaged end to release from the slot in the throttle wheel and then pull the inner cable out through the mounting plate hole.

If you will reuse the cable wash all components in non-flammable cleaning solvent, carefully blow all parts dry with low pressure compressed air, replace the control cables if frayed, kinked or bent, put one or two drops of oil into the housing of each control cable.

INSTALLATION
Apply a light coating of graphite to the handlebar and to the inside surface of the housings, attach the control cable assemblies to the lower housing, push the silver insert of the throttle cable housing into the hole in front of the tension adjuster screw, push the gold insert of the idle cable housing into the hole at the rear of the tension adjuster screw, install the adjusting screw, spring and friction pad in the lower housing if they were removed, position the throttle grip on the handlebar, place the lower housing on/over the throttle grip, position the ferrules and retaining rings over the cable balls and seat them in the throttle notches, fasten the upper housing to the lower housing using two screws tightened to 35-45 in-lbs (4.0-5.1 Nm), CHECK the throttle cable routing, on FXD, FXDL and FXDX models, the throttle cables are routed between the headlamp bracket and the front fork upper bracket and then under right side of tank to carburetor. On FXDXT models the throttle cables are routed through a wire form that is mounted on the upper fork bracket. On FXDWG models, the throttle cables are routed behind the front fork upper bracket, then under the right side of the fuel tank to the carburetor, install the throttle cables on the carburetor and adjust them at the handlebars and re-install the air cleaner. The throttle cables must be clear of steering stops and not be so tight that the idle speed will be changed when turned from steering stop to steering stop.

Throttle Cable Adjustment
To adjust the throttle cables turn the cable adjusters and jamnuts as short as they will go so that both cables will have zero adjustment at the start of the adjustment procedure. THEN with the front wheel pointing straight ahead turn the throttle grip wide open and hold it there, turn the throttle cable adjuster to lengthen the sleeve until the throttle cam just touches the cam stop. THEN tighten the adjuster jamnut and release the throttle. THEN turn the front wheel full right and turn the idle cable adjuster to lengthen the sleeve until the cable housing just touches the spring in the cable support sleeve. THEN recheck the adjustment by working the throttle grip to be sure the cable returns to idle position when released. If the cable does not return to idle, turn idle adjuster to shorten the sleeve until the correct adjustment is reached and then tighten the jamnut. The throttle control must operate freely without binding.

What year model. Take tank off. Take cover off throttle on handle bars. Release tension on throttle cable by loosening cable adjusters. Release cable from carburetor. Release cable from throttle housing on handle bar. Reverse instruction to install new cables ...2 cables.

There are two cables leading to the throttle. Both have two pieces.
Cable 1 goes from the throttle about 12" long and connects to an adjustment piece joining it to cable2 which goes to the throttle body.
Cable 3 also goes from the throttle and is about 12" long and connects to and adjustment piece joining it to cable 4 which goes to the spring on the throttle body.
To change any of them you must loosen the adjustment piece until the ends can be removed from it.
Then to change cables 1 and 3 you have to remove the throttle cover on the grip. you will be able to see how they are removed. Then reverse these steps to install the new cable.
To change cables 2 and 4 in no more difficult but more time consuming as you will have to route these longer cables from the adjuster to where they connect to the throttle body.
When cables have been install and all parts reassembled you can carefully adjust the tension on the cables until the throttle responds the way you like it.
Hope this helps

To replace the throttle cable, first loosen the adjustment on both cables getting as much slack as possible in both cables. Then remove the two screws that hold the right switch housing together. Carefully seperate the two halves of the switch housing. Work the cable out of their slots in the throttle sleeve. Do not lose the ferrels on the ends of the cables but do take them off. Work the broken cable out of the lower switch half.

To get the cable loose from the carburetor, you'll probably have to remove the fuel tank. With the fuel tank off, you can work the cable out of the cable stop and then out of the throttle plate linkage on the carburetor.

To install the new cable, first slide the new cable up through the hole in the lower switch housing. Then put the ferrels on the ends of both cables and work them back into their slots in the throttle sleeve. Carefully reassemble the switch housing halves back together being careful not to pinch any wires.

Then reconnect the cable at the carburetor throttle plate linkage and insert the new cable in the cable stop. Adjust the cable so that you have just a bit of freeplay in them and check to see if the throttle will snap closed on it's own when cranked to wide open throttle position and release. Make certain that the throttle works correctly. Put the fuel tank back on.

Good Luck
Steve

On the carburetor hold the throttle lever to where it would be at full throttle. Then you can put the cable back in the catch for the cable that is on the throttle lever and let go of the throttle lever. The throttle cable should work with the throttle trigger now. The throttle cable only fits one way. The larger hole on the throttle cable catch should go to the ball at the end of the cable.
I hope this helps.
If you feel you cannot do this, then I would take it into your closest Stihl dealer and ask them if they would help you. I do this small repair for free at my shop. Have a good day.

Idle Air Control Valve Pintle may be bad If you disconnect the IAC and the problem ceases it can point to this being the problem.: Removal & Installation 3.5L Engine To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the fuel injector sight shield.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • The air cleaner intake duct. Figure of IAC and TPS electrical connectors disconnected.
     
     
   • The idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Figure of cruise control and throttle control cables removed from throttle lever.
     
     
   • The cruise control cable and throttle control cable from the throttle body lever.
   • The fuel pressure regulator vacuum hose, positive crankcase ventilation (PCV) hose and the throttle body vacuum port hose.
   • The throttle body coolant hoses.
   • The throttle control cable bracket, leaving the throttle and cruise cables connected.
   • The upper nut holding the throttle body to the intake manifold.
   • The throttle body assembly.
5. Clean the gasket mating surfaces.

To Install:

1. Install a new gasket and new studs if necessary.
2. Install or connect the following:
   • The throttle body assembly.
   • Start the top nut by hand.
   • The throttle body coolant hoses.
   • Position the throttle control cable bracket and hand start the retaining nuts and bolt.
   • Torque the three throttle body retaining nuts to 89 in.lbs. (10 Nm). And the bracket retaining bolt to 115 in.lbs. (13 Nm).
   • The throttle body vacuum port hose, PCV valve hose and the fuel pressure regulator hose.
   • The throttle control and cruise control cables to the throttle body lever.
   • The IAC valve and TP sensor electrical connectors.
   • The air intake duct.
3. Refill the cooling system.
4. Install the fuel injector sight shield.

4.0L Engine To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable.
   • The Mass Air Flow (MAF) sensor electrical connector.
   • The air cleaner intake duct.
   • The PCV valve fresh air tube. Figure of cruise control cable removed from throttle cable bracket.
     
     
   • The cruise control cable and throttle control cable from the bracket.
   • The cruise control cable and throttle control cable from throttle body lever. Figure of IAC valve and TPS connectors removed.
     
     
   • The idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Figure of fuel lines removed from retainer on throttle cable bracket.
     
     
   • The fuel feed and return lines from the retainer on the throttle control cable bracket.
   • The transaxle shift cable clip from the throttle control cable bracket. Figure of throttle body removed from water crossover.
     
     
   • The throttle body from the water crossover.

To Install:
NOTE: The Mass Air Flow (MAF) sensor inlet and the outlet of the air cleaner assembly must line up when installed. Misalignment may cause MIL illumination or driveability concerns.

1. Install or connect the following.
   • The throttle body to the water crossover. Torque the bolts to 106 in.lbs. (12 Nm).
   • The IAC valve and TP sensor electrical connectors.
   • The throttle and cruise control cables to the throttle body lever.
   • The throttle and cruise control cables to the throttle control cable bracket. The transaxle shift cable clip to the throttle control cable bracket.
   • The fuel feed and return line retainer to the throttle control cable bracket.
   • The MAF sensor electrical connector.
   • The air cleaner intake duct clamp. Torque the clamp to 27 in.lbs. (3Nm).
   • The PCV valve fresh air tube.
   • The fuel injector sight shield. Torque the nuts to 20 in.lbs. (2.3 Nm).
2. Install the negative battery cable.
3. Pressurize the fuel system and verify no leaks.

Ok, I'm not very familiar with fuel injected models because I don't work on them but they should have a throttle cable like anything else. In the cable somewhere (usually close to the throttle grip) it has an adjuster. There should be two cables, a throttle cable and an idle cable. The throttle cable is the cable towards the front of the bike at the throttle mechanism as it pulls the throttle open. Loosen the lock nut and adjust the cable to take most but not all the slack out of the cable. You must have a bit of slack in each cable for the throttle to work freely. Do the same with the idle cable nearest the rear of the bike.
Once finished, with the engine off, twist the throttle grip to the wide open throttle position and release it. It should snap shut. If it doesn't it's not adjusted correctly. Readjust the throttle cable and idle cable until the throttle operates properly. You must get this right.

Failure to properly adjust the throttle cables could result in the loss of control of the bike resulting in serious injury or death. If you are not sure of how to do this, find someone who knows how to do it. You don't want your throttle sticking on you.

Good Luck
Steve

I'm sorry but I can't send a diagram via this site. I have no idea where I can get a diagram either.

But, to replace the throttle grip on your Softail, you'll see the not only are you replacing but you're replacing the throttle sleeve as well. This actually makes it easier.

To replace the grip, first loosen the throttle and idle cables as loose as you can at the adjusters close to the throttle grip. Then remove the screws that hold the two halves of the throttle switch housings together. Carefully seperate the housing halves as much as the wires will allow.

You'll see the cables coming up and connecting to the throttle sleeve. Each cable will have a ball and a ferrell on it. Work both cables loose and slide the throttle sleeve off the handlebar.

Now, lubricate the inside of the new throttle sleeve, the cable area of the throttle sleeve and the handlebar with fresh white lithium grease. Slide the throttle sleeve up on the handlebar and work the cables back into the throttle sleeve. Be careful not to lose the ferrells. They must be in there for the throttle to work properly.

Once you get the cables installed into the sleeve, put the switch housings together and install the bolts. Before tighten the bolts slide the throttle up onto the handlebar until it stops. Then back if off about 1/8 to 1/4" or so. Tighten the bolts. Readjust the cables leaving just a bit of slack in the throttle cable.

With the engine off, twist the throttle to wide open throttle and let go of the throttle grip. The throttle should snap shut. If not, loosen the cables a bit or back the throttle grip a bit further off the handlebars. The throttle grip must work correctly or serious injury or death may result. This job must be done correctly. It's not difficult just make sure it's right.

Good luck
Steve

If you're talking about the old style throttle cable that is internal of the handlebar, it's pretty straight forward. Remove the throttle grip, the rollers and pin for the plunger. Pull the plunger out bringing the old throttle cable with it or at least out far enough to loosen the small set screws that lock the cable in. Now, run the new cable through the outer housing. put the end of new cable into the plunger and tighten the set screws. Replace plunger into the handlebar, replace pin and rollers, replace throttle grip. Now, set the throttle to full closed posititon. Move carb throttle lever to full closed position. With throttle cable through clamp tighten screw securing cable. Check for proper operation of throttle mechanism.