Throttle cable replacement - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
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post #1 of 9 Old 04-09-2018, 02:35 AM Thread Starter
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Throttle cable replacement

It finally happened. I was about half a mile from home tonight when one of my throttle cables simply stopped working. Naturally, it was the one that opens the throttle, so I ended up pushing my DL1000 home. Boy was that "fun."

My "warning" was that the throttle got sticky for a few minutes. It seemed to take an inordinate amount of force to open the throttle, but it closed normally. I had about enough time to think "Huh, that's weird, should probably look at that when I get home" when the throttle stopped working altogether (other than going closed).

Any tips on swapping the cables? The shop manual doesn't show the procedure, unless I missed something. It only shows how to adjust them post-installation.

This post (https://www.stromtrooper.com/maintena...placement.html) makes the job sound awful, but the single reply makes it sound not so bad after all.

I would think I'm in for lifting the tank, at least, if only to get at where the cables attach to the throttle bodies & be able to route them through the bracket that holds them to the frame behind the triple tree.

I searched this board too, but only found general comments on how to replace the cables, not anything like a detailed walkthrough. Does one exist?

Should I get a set of OEM throttle cables, or are there worthy aftermarket replacements?

FWIW, the cable seems to have broken where it was brushing up against some sharp part of my Strebel horn over who-knows-how-long a period.
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post #2 of 9 Old 04-09-2018, 09:32 AM
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Are there any throttle cable vids or pics in the BlackLab entries?
https://blacklabadventures.com/
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post #3 of 9 Old 04-09-2018, 05:49 PM Thread Starter
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No unfortunately not.

Not having luck elsewhere either.

I had another look at stuff this morning. I'm really perplexed. Turning the forks all the way from one side to the other, the cables did not touch anything anywhere near the point of the break.

update: ok, looks like they SOMETIMES touch a sharp corner on the bracket that holds the Strebel horn in place. Why this wasn't a problem for the previous 16000 miles, but suddenly sawed through the cable, is a mystery. Or maybe it just took a really long time?

In any case, I'm down for closer to 2 weeks if I'm replacing with stock cables. I called Partzilla this morning & they do not stock replacement cables. The local Suzuki dealer, like most motorcycle shops, is not open on Mondays, but I doubt they stock cables for a 10 year old bike either.

I'd rather have OEM, but hell, if I can get aftermarket cables sooner, that's what I'll do.

2007 Vee

Last edited by DesertBike; 04-10-2018 at 12:24 AM.
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post #4 of 9 Old 04-10-2018, 03:03 PM Thread Starter
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Local Suzi shop was looking at the same 5-7 business day wait for shipping.

Rocky Mountain ATV had the Motion Pro cables in stock, so I ordered a set. Came out to about the same price as OEM cables, even with 2-day shipping. Not too shabby!

Since a walkthrough doesn't seem to exist, I'll take some photos and show the process of replacing the throttle cables.

2007 Vee
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post #5 of 9 Old 04-11-2018, 08:45 PM Thread Starter
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Well, crap. :(


This is what I saw when I suddenly had no throttle response. Looking up and to the bike's left from in front of the forks, just to the right of the front fender.

Near the top middle of the picture is the throttle pulling cable (#2 in shop manual terms) that's been just about cut clean through, somehow.

It also turns out my left fork is leaking a bit. FML.
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post #6 of 9 Old 04-12-2018, 11:42 PM Thread Starter
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Got the plastics and crash bars pulled, tank lifted, airbox removed this evening.

Now it's down to removing the old throttle cables & installing & routing the new.

It's not too tough once you have all that done. There's limited room to swing a wrench to loosen the nuts that hold the throttle body ends of the throttle cables in place though. I'm glad I bought that tiny adjustable wrench (1/2" max. opening) a while back.

Throttle cables connect to the left side of the rear throttle body. Is there any reason one can't route the cables to the right of the steering stem? There's a threaded hole for the associated bracket on both sides. Seems to me it would make sense to route the cables right rather than left, since they're going to the right side of the handlebars.
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post #7 of 9 Old 04-13-2018, 08:15 PM Thread Starter
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FWIW, it turns out swapping the throttle cables is covered well in the Clymer Vstrom DL650 manual.

There are some small differences between model years, but the DL1000 and DL650 throttle designs are similar enough that you can go by the Clymer pics if working on a Vee (at least a first-generation Vee; dunno about the Vee2 as it has a different engine).

Some observations, to help anyone doing this job in the future:

-You'll want a set of stubby open-end wrenches, because there's not much room to swing a wrench without hitting the frame. Maybe even some kind of ratcheting open-end wrench. I just bought a set of stubby open-end wrenches at Horrible Freight because it was cheap and quick and I'm pretty sure I'll need them for other jobs.

-You'll have to use one wrench to hold the locking nut while you turn the hexagonal fitting body about 1/3 a turn at a time. It's tedious. Take your time.

-The locking nuts that locate the throttle-body-ends of the cables, are 12mm. The longer, threaded body of this end of the cable takes a 10mm wrench.

-It's not too difficult to keep straight which cable is which. Don't know whether it was intentional, but my Motion Pro cable set uses slightly different finishes on the metal fittings to distinguish one cable from the other, as well as the fact they will only install one way in the casing on the handlebar.

-Do take note of how the existing cables are installed, and maybe some photos, before you remove anything. Take some time to observe and understand the principle of operation. It works the same way at the throttle bodies.

-I recommend doing the handlebar end of the job first, both because it's easier, and because then you can work the throttle to remind yourself which cable does what, when you're installing the engine-side ends.


Next task is "major adjustment" of the throttle body cable ends, for correct clearance & play.
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post #8 of 9 Old 04-15-2018, 01:34 PM Thread Starter
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It's done!

Still not sure why the original cable got mangled.



Does anyone know what this bit of plastic is? Found it lying in the engine valley after the airbox was off. No idea where it's supposed to go. Do not see it in any of the parts diagrams.

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post #9 of 9 Old 04-15-2018, 01:37 PM
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Believe that is a bumper for under the tank, there are more than one. Good write up, and use a sealmate first before changing seals. Of course if the fluid has never been changed or been a while, might as well change the seals.
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