Throttle cable questions

[Jamesl0822]

I swapped from a E carb to a G carb that john sachs modified for me on my 05 Chopper with S&S Dual Runner. It has the thunder jet on it now and I'm having some issues with the throttle cables.
The return cable kept coming loose in the handle due to excessive play that I could not tighten out with the adjustment (fully extended I had nearly an inch left). I noticed that my old E carb and a different bracket that mounts to the carb itself for the cables to slide into and I thought my issues were over. I swapped out the brackets and put the ferrels in the carb first then moved to the handle and holy crap what a PITA!! Finally got both ferrels in (and in the right direction) but they were so freaking tight with the adjustment all the way in giving it max slack that when I turned the throttle it was really really hard and would not spring back at all.

Has anyone had any issues with cables after switching carbs? I dont' remember which bracket was on my E carb and I only know that when it returned from the shop that this bigger Taller bracket was on the E carb that was on my bike. I'm not 100% which one was on my E carb before it went to the shop.

 

[boomer4444]

just a though but do you have them in the wrong place.as in swap cables positions?

 

[Jamesl0822]

I am thinking this could be the case as well...I have tried both brackets one has too much play and the other not enough. One cable has a spring on it and one doesn't but haven't tried switching them yet...next project in the morning.
I also thought maybe they were routed the wrong way at the handle bar but I don't think thats possible

 

[Jamesl0822]

Definitely not routed wrong and cables were not switched the wrong way. I'm very frustrated. I tried both brackets or guides or whatever the heck you call them. The tall ones are so tight that if I get them on then I can't twist the throttle. The shorter ones have so much slop that the feral on the return side comes off immediately. I tried both twice today and got fed up.

The only possibility that I can come up with is that when I use the shorter one and I have the bottoms hooked to the carb maybe the feral is coming out in the handle before I can tighten any slop out of the line and when I do go to tighten ...it is already loose in the handle?
Tomorrow I will try to start at the handle and put it on the carb while having the adjustments to the least amount of slack I can

Any and all thoughts appreciated

 

[boomer4444]

are you sure you have them routed the right way on the handlebar,,i have never had my dogs apart but have routed other controls and have hooked up wrong and got same result as you are having,hard turn and no return on throttle,recheck how they route up and over the groove inside throttle hand control..bet thats where problem is!!

 

[Slider]

Not sure.

040595: S&S Throttle Cable Guides for Stock Cables

 

[V]

And when you do get them straightened out (you will) look in the carb to make sure when you have the throttle fully twisted that the carb blade is WOT (wide open throttle)

 

[Jamesl0822]

Ok so I have it all figured out but not fixed....yet.
Every time I put the ferals in the handle (last) when I would close up the housing the feral would come loose so I had to start at the handle and finish at the carb with the shorter cable guide.
New problem is that I stretched the cable when I managed to get the cable on with the taller cable guide....:bang:
I am pretty sure this is what happened bc when I installed the cables handle first and carb last it was very close but I couldn't adjust it quite enough to keep the ferals from coming loose but very close. So I took 4 small washers and cut them to fit around the wire at the carb guide as a make shift spacer of about a 1/4 inch or so and bingo I could adjust it. and it works fine but I'm ordering new throttle and idle cables anyway.

Anyone know the correct part numbers for these or length and play?