MotoMaster Motorcycle Throttle Cable B (CLOSE) Instruction Manual

1. Product Overview

This manual provides instructions for the MotoMaster Throttle Cable B (CLOSE), designed as a direct replacement for specific Kawasaki Z 900 series motorcycles. This cable is manufactured to original equipment specifications to ensure proper fit and function, contributing to reliable throttle control.

Image 1.1: Full view of the MotoMaster Throttle Cable B (CLOSE). This image displays the complete cable assembly, including the outer casing and inner wire, designed for precise throttle operation.

2. Compatibility

The MotoMaster Throttle Cable B (CLOSE), model 153-154, is specifically designed for the following Kawasaki motorcycle models:

• Kawasaki Z 900 A (1976)
• Kawasaki Z1 900 (1973)
• Kawasaki Z1A 900 (1974)
• Kawasaki Z1B 900 (1975)

Please verify your motorcycle's make, model, and year against this list to ensure proper fitment before installation.

Image 2.1: Detailed compatibility table showing Kawasaki models and their respective years for which this throttle cable is suitable.

3. Product Features

This MotoMaster throttle cable is engineered with quality materials and manufacturing processes to ensure durability and reliable performance:

• OEM Standard Manufacturing: Produced to meet or exceed original equipment manufacturer specifications for a precise fit and function.
• Durable Construction: Features a high-quality outer wire with Teflon and a durable inner wire made from a corrosion-retardant alloy.
• Reduced Friction: The inside of the outer cable and all metal components are coated with a high-quality polyimide lining to minimize friction and wear.
• Weather Resistance: Oiled with a special compound to resist freezing in low temperatures and reduce dust attraction, preventing brittleness and dust accumulation.
• Longevity: Designed to resist stretching and seizing, increasing the cable's lifespan and resistance to environmental elements.

Image 3.1: Close-up view of a throttle cable end, illustrating the robust construction and fittings. This detail highlights the quality of materials used in the cable's design.

4. Installation Instructions

Safety First: Before beginning any work on your motorcycle, ensure the engine is off, the motorcycle is stable on a stand, and the battery is disconnected to prevent accidental starting or electrical issues. Refer to your motorcycle's service manual for specific torque specifications and procedures.

1. Preparation:
   • Gather necessary tools: wrenches, screwdrivers, cable lubricant, and possibly a service manual for your specific motorcycle model.
   • Locate the existing throttle cable. The "CLOSE" cable typically connects from the throttle grip to the carburetor or throttle body, responsible for closing the throttle.
2. Removal of Old Cable:
   • At the throttle grip, loosen the throttle housing screws and carefully open the housing. Disconnect the cable end from the throttle tube.
   • Follow the cable routing down to the carburetor(s) or throttle body. Disconnect the cable end from the throttle mechanism.
   • Note the routing of the old cable to ensure the new cable is installed correctly, avoiding kinks or sharp bends.
   • Carefully remove the old cable from the motorcycle.
3. Installation of New Cable:
   • Apply a small amount of cable lubricant to the inner wire of the new MotoMaster throttle cable.
   • Route the new cable along the same path as the old cable, ensuring it does not interfere with steering, suspension, or other moving parts.
   • Connect the cable end to the throttle mechanism at the carburetor(s) or throttle body. Ensure it is seated correctly.
   • At the throttle grip, connect the other end of the cable to the throttle tube.
   • Close the throttle housing, but do not fully tighten the screws yet.
4. Adjustment:
   • Ensure there is a small amount of free play (typically 2-3mm) at the throttle grip before the cable begins to pull. This is crucial for safe operation.
   • Adjust the cable tension using the inline adjusters (if present) or the adjusters at the throttle housing/carburetor until the correct free play is achieved.
   • Turn the handlebars from lock to lock to ensure the throttle action remains smooth and consistent throughout the steering range, with no increase in engine RPM.
   • Once satisfied with the adjustment, tighten all lock nuts on the adjusters and the throttle housing screws.
5. Final Check:
   • Before riding, perform a thorough check of the throttle operation. The throttle should snap closed immediately when released.
   • Start the engine and re-check throttle response and return.

Image 4.1: View of the throttle cable, illustrating both connection ends. This helps in identifying the correct orientation and attachment points during installation.

5. Operation and Maintenance

5.1. Operation

Once installed and properly adjusted, the throttle cable facilitates the opening and closing of the throttle mechanism. Ensure the throttle operates smoothly without sticking or binding throughout its full range of motion and returns to the closed position immediately when released. Any resistance or slow return indicates a potential issue that requires immediate attention.

5.2. Maintenance

Regular inspection and maintenance of your throttle cable are essential for safe and reliable motorcycle operation:

• Inspection: Periodically check the entire length of the cable for signs of fraying, kinking, corrosion, or damage to the outer casing. Pay close attention to the ends where the cable connects to the throttle grip and carburetor/throttle body.
• Lubrication: Although MotoMaster cables are pre-lubricated, occasional re-lubrication with a suitable cable lubricant can extend their lifespan and maintain smooth operation. Use a cable luber tool for best results.
• Adjustment Check: Regularly check the throttle free play. If it changes significantly, re-adjust the cable as per the installation instructions.
• Cleaning: Keep the cable and its routing path free from dirt and debris.

Image 5.1: View of a motorcycle handlebar, showing the throttle grip and controls. Regular inspection of this area is crucial for cable maintenance.

6. Troubleshooting

If you experience issues with your throttle operation, consider the following troubleshooting steps:

• Sticky or Slow Throttle Return:
  • Check for proper cable routing. Ensure there are no sharp bends or kinks.
  • Verify adequate free play at the throttle grip.
  • Inspect the cable for internal corrosion or fraying. Lubricate if necessary.
  • Ensure the throttle tube and handlebar are clean and free of debris, allowing the grip to rotate freely.
• Excessive Free Play:
  • Re-adjust the cable tension using the adjusters.
  • Inspect the cable for stretching, which may indicate it needs replacement.
• Throttle Not Fully Closing:
  • Check for obstructions in the throttle mechanism at the carburetor/throttle body.
  • Ensure the cable is not binding anywhere along its path.
  • Verify the cable is correctly seated at both ends.

If issues persist after troubleshooting, it is recommended to consult a qualified motorcycle mechanic.

7. Specifications

8. Support and Contact Information

For any questions regarding the MotoMaster Throttle Cable B (CLOSE) or for further assistance, please contact MotoMaster customer support. You can find more information and contact details on the official MotoMaster store page:

Visit the MotoMaster Store on Amazon

Please have your product model number (153-154) and motorcycle details ready when contacting support.