1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of your Lokar TC-1000HT 24" Hi-Tech Throttle Cable. Please read all instructions carefully before beginning installation or use to ensure proper function and safety.
Image 1.1: Lokar TC-1000HT 24" Hi-Tech Throttle Cable, showing the braided stainless steel housing, adjustable fittings, and cable ends.
2. Safety Information
Always exercise caution when working on vehicle systems. Ensure the vehicle is turned off, cooled down, and properly secured before beginning any work. Wear appropriate personal protective equipment, including gloves and eye protection. Improper installation or adjustment of the throttle cable can lead to unintended acceleration or other dangerous conditions. If you are unsure about any step, consult a qualified mechanic.
3. What's in the Box
The Lokar TC-1000HT 24" Hi-Tech Throttle Cable package typically includes the following main components:
- 24-inch Braided Stainless Steel Throttle Cable Housing
- Stainless Steel Inner Wire
- Adjustable Fittings (Ferrule, Adjuster Nuts, Carb End Assembly)
- Clevis
- Firewall Fitting
- Hex Key Wrench for adjustments
Please inspect all components upon receipt to ensure everything is present and undamaged.
Video 3.1: Unboxing and overview of a 24" universal throttle cable kit, showing the braided cable, various fittings, and adjustment tools.
4. Setup and Installation
The Lokar TC-1000HT throttle cable is designed for a custom fit and may require cutting the outer housing and inner wire to the appropriate length. Follow these general steps for installation:
4.1. Prepare the Cable
- Disassemble the Cable Ends: Carefully remove the inner wire from the cable housing by loosening the set screws on the adjuster nuts and carb end assembly. Keep all small parts organized.
- Measure and Cut the Housing: Route the cable housing from the throttle body/carburetor to the firewall, ensuring it follows a path free from kinks, sharp bends, and moving parts. Measure the required length, allowing for proper movement and adjustment. Use a specialized cable cutter or fine-toothed hacksaw to cut the braided stainless steel housing. Ensure a clean, square cut.
- Cut the Inner Wire: Once the housing is cut and fittings are reassembled, pull the inner wire taut and mark the excess. Cut the inner wire, leaving approximately 1/2 inch beyond the cable end stop for future adjustments.
Video 4.1: Demonstration of disassembling and cutting a universal 24" throttle cable for custom fitment, highlighting the inner wire and outer housing.
Video 4.2: Detailed steps on how to cut the inner wire and outer housing of a universal throttle cable, and reassemble the fittings.
4.2. Install Firewall Fitting
- Insert the firewall fitting through the firewall from the engine side. Secure it with the provided nuts.
4.3. Connect to Throttle Pedal
- Connect the clevis on the new throttle cable to the throttle pedal. Ensure it allows for full range of motion without binding.
4.4. Connect to Throttle Body/Carburetor
- Install the throttle body fitting onto the end of the inner wire.
- Attach the cable to the throttle arm on the carburetor/throttle body.
4.5. Adjust Cable Tension
- With the throttle in the idle position, adjust the cable adjuster nuts to remove any slack in the cable.
- Depress the throttle pedal to its full extent. Ensure the throttle opens completely without binding and returns smoothly to idle. Make fine adjustments as needed.
5. Operating the Throttle Cable
Once properly installed and adjusted, the Lokar TC-1000HT throttle cable provides a smooth and responsive connection between your accelerator pedal and the engine's throttle. The braided stainless steel housing ensures minimal friction and consistent performance. Always ensure the throttle returns to the idle position when the pedal is released.
6. Maintenance
To ensure the longevity and optimal performance of your Lokar throttle cable, perform the following maintenance:
- Regular Inspection: Periodically check the entire length of the cable, including fittings and connections, for any signs of wear, fraying, or damage.
- Lubrication: Apply a small amount of appropriate cable lubricant to the inner wire and fittings annually or as needed to maintain smooth operation.
- Cleanliness: Keep the cable and its components free from dirt, grime, and corrosive materials.
- Adjustment Check: Verify that the cable tension remains correct and that the throttle operates freely through its full range of motion.
7. Troubleshooting
If you experience issues with your throttle cable, consider the following:
- Sticking or Binding Throttle:
- Check for kinks or sharp bends in the cable routing.
- Ensure fittings are not overtightened or misaligned.
- Lubricate the inner wire.
- Inspect the throttle pedal and throttle body linkage for obstructions or damage.
- Excessive Slack:
- Adjust the cable adjuster nuts to remove slack.
- Ensure the cable end stop is securely fastened.
- Incomplete Throttle Opening/Closing:
- Verify that the cable length is correct and allows for full travel.
- Check for proper installation of the clevis and throttle body fitting.
8. Specifications
| Model Number | TC-1000HT |
| Cable Length | 24 inches |
| Material | Braided Stainless Steel Housing, Stainless Steel Inner Wire |
| Fit Type | Vehicle Specific (Universal Cut-to-Fit) |
| Item Weight | 4.6 ounces |
| Country of Origin | United States |
9. Warranty and Support
Lokar provides American Made, quality products to all customers, backed by a Lifetime Warranty. For technical support, troubleshooting assistance, or warranty claims, please contact Lokar customer service directly.
