1. Product Overview
This document provides essential information for the installation, operation, and maintenance of your MOTOMASTER Motorcycle Throttle Cable Set. This set includes both the OPEN and CLOSE throttle cables, designed to meet original equipment specifications for a precise fit and reliable performance.
Image 1.1: Complete MOTOMASTER Motorcycle Throttle Cable Set. This image displays the full throttle cable assembly, including both the 'open' and 'close' cables, with their protective sheathing and end fittings.
2. Compatibility
This MOTOMASTER Throttle Cable Set is specifically designed for the following Kawasaki motorcycle models:
| Brand | Model | Start Year | End Year |
|---|---|---|---|
| Kawasaki | ZX-6R 600 G Ninja | 1998 | 1999 |
| Kawasaki | ZX-6R 600 H Ninja catalyst | 1998 | 1999 |
Image 2.1: Visual representation of the compatibility table. This image shows a table detailing the specific Kawasaki ZX-6R models and years that are compatible with this throttle cable set.
Please verify your motorcycle's make, model, and year against this table to ensure proper fitment before installation.
3. Product Features and Specifications
3.1 Key Features
- OEM Standard Manufacturing: Produced according to original equipment manufacturer (OEM) standards and in original sizes for a perfect fit.
- High-Quality Construction: Features a durable outer wire with Teflon and a corrosion-retardant alloy inner wire.
- Enhanced Durability: Cables are oiled with a special compound to resist freezing in low temperatures and prevent dust attraction.
- Reduced Friction: The inside of the outer cable and all metal components are coated with a high-quality polyimide lining to protect the inner cable from friction and wear.
- Resistant to Stretching: Designed with a durable inner cable to reduce the likelihood of stretching or seizing, increasing resistance to environmental elements.
3.2 Specifications
- Brand: MotoMaster
- Manufacturer Part Number: 153-318
- OEM Number: 54012-1566
- Package Quantity: 1 Piece Throttle Cable Set (OPEN and CLOSE)
- Color: Black
- Condition: New
- Item Weight: Approximately 7.8 ounces
- Package Dimensions: Approximately 10.08 x 9.49 x 0.67 inches
4. Setup and Installation
Installation of throttle cables requires mechanical aptitude and appropriate tools. If you are not confident in your ability to perform this installation, it is recommended to seek assistance from a qualified motorcycle mechanic.
4.1 General Installation Guidelines:
- Safety First: Ensure the motorcycle is on a stable stand, the engine is off, and the ignition is turned off. Disconnect the battery if necessary.
- Access: Remove any fairings, fuel tank, or other components necessary to gain clear access to the throttle body/carburetors and the throttle housing on the handlebar.
- Disconnect Old Cables: Carefully disconnect the old throttle cables from both the throttle housing and the throttle body/carburetors. Note the routing of the old cables.
- Install New Cables: Route the new MOTOMASTER throttle cables in the same path as the original cables, ensuring they are not kinked, pinched, or obstructed by moving parts.
- Connect Ends: Attach the new cables to the throttle body/carburetors and the throttle housing. Ensure all fittings are securely seated.
- Adjust Tension: Adjust the cable tension at both the throttle housing and the carburetor/throttle body adjusters to achieve the recommended free play in the throttle grip. Consult your motorcycle's service manual for specific free play specifications.
- Test Operation: With the engine off, rotate the handlebars from lock to lock and ensure the throttle operates smoothly without binding or changing engine RPM (if connected). The throttle should snap back to the closed position freely.
- Final Checks: Reinstall all removed components. Start the engine and perform a final check of throttle operation and idle speed.
Image 4.1: Close-up view of the throttle cable ends designed for connection to the handlebar throttle housing. This image highlights the threaded adjusters and cable barrels.
Image 4.2: Close-up view of the throttle cable ends designed for connection to the carburetor or throttle body. This image shows the specific fittings for the engine side.
Image 4.3: Combined view of both the handlebar and engine-side cable ends. This image provides a comprehensive look at the different termination points of the throttle cable set.
5. Operation
Once properly installed and adjusted, the MOTOMASTER throttle cables will provide smooth and responsive throttle control. Always ensure the throttle operates freely and returns to the closed position without assistance.
- Smooth Action: The throttle grip should rotate smoothly and consistently throughout its range of motion.
- Positive Return: Upon release, the throttle grip must snap back to the idle position immediately and completely.
- No Binding: Check for any binding or sticking of the throttle cables, especially when turning the handlebars fully left or right.
6. Maintenance
Regular maintenance of your throttle cables is crucial for safety and longevity.
- Inspection: Periodically inspect the entire length of the cables for signs of fraying, kinking, corrosion, or damage to the outer casing.
- Lubrication: While MOTOMASTER cables are pre-lubricated, occasional re-lubrication with a suitable cable lubricant can extend their lifespan, especially in harsh environments. Use a cable luber tool for effective application.
- Adjustment: Check and adjust throttle cable free play regularly according to your motorcycle's service manual. Excessive free play can lead to delayed throttle response, while too little can cause the throttle to stick open.
- Cleaning: Keep the visible parts of the cables clean from dirt and debris.
7. Troubleshooting
If you experience issues with your throttle operation, consider the following troubleshooting steps:
- Throttle Sticking/Binding:
- Check cable routing for kinks or pinches.
- Ensure cable adjusters are not overtightened, causing tension.
- Inspect the throttle grip and housing for internal obstructions or damage.
- Lubricate cables if they feel dry.
- Excessive Free Play:
- Adjust cable tension at the handlebar and/or carburetor/throttle body adjusters.
- If cables stretch significantly and cannot be adjusted, replacement may be necessary.
- Poor Throttle Response:
- Verify correct cable routing and adjustment.
- Ensure the throttle mechanism on the carburetor/throttle body moves freely.
- Cable Fraying/Damage:
- Immediately replace any cable showing signs of fraying, kinking, or damage to prevent failure.
8. Support and Contact Information
For further assistance, questions regarding installation, or product support, please contact MotoMaster customer service. Always refer to your motorcycle's official service manual for detailed, model-specific instructions and safety warnings.
You can visit the MotoMaster store for more information and products: MotoMaster Store on Amazon