JFG RACING Throttle Tube Instruction Manual

1. Product Overview

The JFG RACING Throttle Tube is a high-quality replacement component designed for specific motorcycle models. It is engineered to provide ultra-smooth and precise throttle twist, enhancing the riding experience. The sealed ball bearing system virtually eliminates friction, ensuring reliable performance.

Image 1.1: Main view of the JFG RACING Throttle Tube, showing the gold-anodized aluminum tube and black rubber bar end plugs.

Image 1.2: Visual representation of key product features including smooth rotation, easy installation, high-quality material, and CNC machining.

2. Fitment Information

This throttle tube and handlebar grip set is designed to fit the following motorcycle models:

• DRZ400R: 2000-2019
• DRZ400S: 2000-2019
• DRZ400SM: 2000-2019
• DR250S: 1992-2004
• DR250R: 1992-2004

Ensure your motorcycle model and year match the listed fitment to guarantee proper compatibility and performance.

Image 2.1: Visual confirmation of compatible motorcycle models and key product benefits.

3. Package Contents

The package includes the following components:

• 1x Throttle Tube Handlebar (Gold, Aluminum)
• 2x Grips Bar End Slider Cap Plugs (Black, Rubber)
• Additional Plug Adapters (12mm, 14mm, 16mm)

Please verify all components are present upon opening the package.

Image 3.1: All components included in the package: the throttle tube, two bar end plugs, and additional rubber adapters.

4. Specifications

Image 4.1: Detailed dimensions of the throttle tube, including length and diameter.

Image 4.2: Summary of specifications for the throttle tube and bar end plugs, including measurements.

5. Installation Guide

This JFG RACING Throttle Tube is designed as a direct OEM replacement. While installation does not require additional modifications, basic mechanical knowledge and appropriate tools are recommended. If you are unsure about the installation process, it is advisable to seek professional assistance.

5.1. Tools Required (Typical)

• Screwdriver (Phillips or Flathead, depending on existing grips/throttle housing)
• Hex keys/Allen wrenches (for bar end weights or clamps, if applicable)
• Grip glue (optional, for new grips)
• Clean cloth

5.2. Installation Steps

1. Prepare the Motorcycle: Ensure the motorcycle is stable and turned off. If possible, secure it on a stand.
2. Remove Old Bar End Plugs (if present): Use appropriate tools to remove any existing bar end weights or plugs from the right handlebar.
3. Remove Old Throttle Grip: Carefully slide off the old throttle grip from the throttle tube. If it's glued, you may need to cut it or use compressed air to loosen it.
4. Remove Old Throttle Tube: Disconnect the throttle cables from the old throttle tube. Note how they are routed and connected to ensure correct reassembly. Remove the old throttle tube from the handlebar.
5. Clean Handlebar: Thoroughly clean the handlebar surface where the new throttle tube will sit to remove any old glue residue or dirt.
6. Install New Throttle Tube: Connect the throttle cables to the new JFG RACING throttle tube. Ensure the cables are properly seated in the grooves. Slide the new throttle tube onto the handlebar. Verify that it rotates smoothly without binding.
7. Install New Grip (if applicable): If installing a new grip, apply a thin layer of grip glue (if using) to the inside of the grip and slide it onto the throttle tube. Allow glue to dry as per manufacturer's instructions.
8. Install Bar End Plugs: Insert the JFG RACING bar end slider cap plugs into the end of the handlebar. Use the appropriate adapter (12mm, 14mm, or 16mm) to ensure a snug fit.
9. Test Throttle: Before riding, thoroughly test the throttle for smooth operation. Ensure it returns to the closed position freely and that there is no binding or excessive play. Check for full range of motion.

Important: The throttle tube should rotate freely and smoothly without any drag or catching at any point in its travel. If you experience any issues, re-check the cable routing and installation.

6. Operating Instructions

Once installed, the JFG RACING Throttle Tube operates identically to your motorcycle's original throttle tube. Its primary function is to provide a smooth and precise connection between your hand's input and the motorcycle's engine throttle. The sealed ball bearing design ensures minimal friction, resulting in an ultra-smooth twist action and immediate throttle response.

Always ensure the throttle returns to the idle position freely when released. Regular checks of throttle function are part of routine motorcycle safety.

7. Maintenance

The JFG RACING Throttle Tube is constructed from durable 6061-T6 aluminum and designed for longevity with minimal maintenance. However, to ensure optimal performance and extend the lifespan of the component, consider the following:

• Regular Inspection: Periodically inspect the throttle tube for any signs of wear, damage, or corrosion. Check the bar end plugs for secure fitment.
• Cleaning: Keep the area around the throttle tube and grips clean. Dirt and debris can impede smooth operation. Use a soft cloth and a mild cleaner if necessary, avoiding harsh chemicals that could damage the finish or rubber components.
• Lubrication: While the sealed ball bearing system is designed to be low-friction, occasional light lubrication of the throttle cables (as per your motorcycle's service manual) can further enhance overall throttle smoothness. Do not apply excessive lubricant directly to the throttle tube's internal mechanism unless specifically instructed by a professional.
• Cable Adjustment: Ensure throttle cable free play is adjusted according to your motorcycle manufacturer's specifications. Incorrect cable tension can affect throttle response and safety.

8. Troubleshooting

If you encounter any issues with your JFG RACING Throttle Tube, consider the following common points:

• Throttle Sticking or Not Returning Freely:
  • Check throttle cable routing for kinks or binding.
  • Ensure the throttle tube is not rubbing against the handlebar or throttle housing.
  • Verify that the throttle cables are properly connected and adjusted.
  • Inspect for any debris or foreign objects obstructing the throttle mechanism.
• Excessive Play in Throttle:
  • Adjust throttle cable free play according to your motorcycle's service manual.
  • Ensure the throttle tube is correctly seated on the handlebar.
• Bar End Plugs Loose:
  • Ensure the correct size adapter (12mm, 14mm, or 16mm) is used for your handlebar's inner diameter.
  • Tighten the screw on the bar end plug if it's designed to expand for a tighter fit.

If problems persist after checking these points, it is recommended to consult a qualified motorcycle mechanic or contact JFG RACING customer support for further assistance.

9. Warranty and Support

For information regarding product warranty, returns, or technical support, please refer to the purchase documentation or contact the seller directly. JFG RACING is committed to providing quality products and customer satisfaction.

You can find more information about JFG RACING products and support on their official channels or through the retailer where the product was purchased.

Image 9.1: JFG RACING brand logo.