1. Introduction
This manual provides essential information for the installation, operation, and maintenance of your MotoMaster Motorcycle Throttle Cable Set. This set includes both PULL and PUSH cables, designed for specific Yamaha XTZ 750 Super Tenere models. Please read this manual thoroughly before installation to ensure proper function and safety.
2. Product Overview
The MotoMaster Throttle Cable Set is engineered to meet or exceed original equipment specifications, ensuring a precise fit and reliable performance for compatible Yamaha motorcycles. These cables are designed for durability and smooth operation, featuring advanced materials and construction methods.
Image 1: Complete MotoMaster Throttle Cable Set (Pull/Push).
Key Features:
- OEM Standard Manufacturing: Produced to original equipment specifications for a perfect fit.
- High-Quality Materials: Features a durable outer wire with Teflon and a corrosion-retardant alloy inner wire.
- Enhanced Durability: Production methods reduce friction and increase resistance against premature breakage.
- Weather Resistance: Cables are oiled with a special compound to resist freezing in low temperatures and prevent dust attraction.
- Polyimide Lining: The inside of the outer cable and all metal components are coated with high-quality polyimide lining to protect the inner cable from friction.
3. Compatibility and Fitment
This throttle cable set is specifically designed for the following Yamaha motorcycle models:
Image 2: Compatibility Table for Yamaha XTZ 750 Super Tenere Models.
| Brand | Model | Start Year | End Year |
|---|---|---|---|
| Yamaha | XTZ 750 H Super Tenere | 1989 | 1997 |
| Yamaha | XTZ 750 N Super Tenere | 1990 | 1993 |
Before proceeding with installation, verify that your motorcycle's make, model, and year align with the compatibility information provided. If you have any doubts, consult a qualified mechanic or contact MotoMaster support.
4. Installation Instructions
Installation of throttle cables requires mechanical aptitude and proper tools. If you are unsure about any step, it is recommended to seek professional assistance. Always refer to your motorcycle's specific service manual for detailed instructions and torque specifications.
Safety Precautions:
- Ensure the motorcycle is on a stable stand and the engine is off and cool.
- Disconnect the battery's negative terminal before starting work to prevent accidental electrical shorts.
- Wear appropriate personal protective equipment (PPE), including gloves and eye protection.
- Work in a well-ventilated area.
Procedure:
- Preparation: Remove any fairings, fuel tank, or airbox components necessary to access the carburetor/throttle body and the throttle housing on the handlebar.
- Disconnect Old Cables:
- At the handlebar, loosen the throttle housing screws and carefully separate the housing. Disconnect the old throttle cables from the throttle tube.
- At the carburetor/throttle body, locate the throttle cable attachment points. Loosen the adjusters and carefully remove the cable ends from the throttle cam/pulley.
- Note the routing of the old cables to ensure the new cables are routed correctly, avoiding kinks or sharp bends.
- Install New Cables:
- Route the new MotoMaster throttle cables along the same path as the old ones. Ensure they are not pinched or rubbing against other components.
- Attach the carburetor/throttle body ends of the new cables to the throttle cam/pulley. Ensure the cable ends are seated correctly.
- At the handlebar, connect the new cables to the throttle tube. The "pull" cable typically connects to the upper part of the throttle tube, and the "push" cable to the lower part. Refer to your motorcycle's service manual for exact configuration.
Image 3 & 4: Detailed views of the throttle cable ends, showing the adjuster and cable attachment points.
- Adjust Cable Slack:
- Adjust the cable slack using the inline adjusters on the cables and/or the adjusters at the carburetor/throttle body.
- There should be a small amount of free play (typically 2-3mm) at the throttle grip before the cables begin to pull. This prevents the throttle from sticking open.
- Ensure the throttle returns smoothly and completely to the closed position when released. Turn the handlebars from lock to lock to check for any changes in throttle operation, which could indicate improper routing or tension.
- Reassemble: Reinstall all removed components (throttle housing, fairings, fuel tank, airbox) in reverse order. Ensure all fasteners are tightened to the manufacturer's specified torque.
- Final Check: Before riding, perform a thorough check of the throttle operation. Start the engine and ensure the idle speed is stable and the throttle responds correctly.
5. Operation and Function
The throttle cable set facilitates the control of your motorcycle's engine speed. The "pull" cable opens the throttle butterflies, increasing engine RPM, while the "push" cable assists in closing the throttle, ensuring a positive return to idle and preventing sticking.
Properly installed and adjusted cables ensure smooth and responsive throttle action, which is crucial for safe motorcycle operation. Always ensure the throttle grip has a slight amount of free play and returns freely when released.
6. Maintenance
Regular inspection and maintenance of your throttle cables are vital for safety and longevity.
Recommended Maintenance Schedule:
- Monthly Inspection: Check for smooth operation, proper free play, and any signs of fraying, kinking, or damage to the outer casing.
- Lubrication (Annually or as needed): Although MotoMaster cables are pre-lubricated with a special compound, periodic lubrication can extend their life. Use a dedicated cable lubricant and a cable luber tool to apply lubricant into the cable housing.
- Cleaning: Keep the visible parts of the cables clean from dirt and debris.
- Adjustment Check: Re-check throttle cable free play after any significant temperature changes or if throttle response feels different.
Replace cables immediately if any damage, fraying, or excessive stiffness is observed. Do not attempt to repair damaged cables.
7. Troubleshooting
| Problem | Possible Cause | Solution |
|---|---|---|
| Throttle sticks or is stiff | Incorrect cable routing, insufficient lubrication, damaged cable, throttle housing binding. | Check cable routing for kinks or sharp bends. Lubricate cables. Inspect cables for damage and replace if necessary. Ensure throttle housing is clean and assembled correctly. |
| Excessive throttle free play | Cables stretched, improper adjustment. | Adjust cable slack using the inline adjusters. If cables are excessively stretched, replacement may be necessary. |
| Throttle does not return fully | Too little free play, cable binding, spring issue in carburetor/throttle body. | Increase free play. Check cable routing. Inspect throttle return spring. |
| Engine RPM fluctuates unexpectedly | Cable binding, improper adjustment, air leak. | Check cable routing and adjustment. Inspect for air leaks around intake manifold. |
If troubleshooting steps do not resolve the issue, consult a certified motorcycle mechanic.
8. Specifications
- Product Name: Motorcycle Throttle Cable SET (PULL/PUSH)
- Brand: MotoMaster
- Model Number: 153-248
- Compatible OEM Part Number: 3LD-26302-00
- Material: High-quality outer wire with Teflon, durable inner wire with corrosion-retardant alloy, polyimide lining.
- Package Quantity: 1 Set (includes both Pull and Push cables)
- Color: Black
- Item Weight: 7.8 ounces
- Package Dimensions: 12.99 x 7.09 x 0.79 inches
9. Warranty and Support
Warranty Information:
MotoMaster products are manufactured to high standards. For specific warranty details, please refer to the warranty information provided at the time of purchase or contact MotoMaster customer service. Generally, products are covered against manufacturing defects.
Customer Support:
If you have any questions regarding the installation, operation, or compatibility of your MotoMaster Throttle Cable Set, please contact our customer support team. You can find contact information on the official MotoMaster website or through your point of purchase.
For more information about MotoMaster and our range of products, please visit the MotoMaster Store on Amazon.