DIY Throttle Mod

[Duff]

I claim no ownership of this write up or the photos included in this write up. The original posting can be found at the link following the write up. I used this write up when I modified the throttle on my 2006 GSX-R 750, and it worked wonderfully. I suspect it will work just as great on our 1700's as it did on my GSX-R, and will be knocking it out sometime this week myself before I ride to Indiana this weekend.

Enjoy

heres the supplies needed for the mod. very cheap and easy. i needed a 1" pcv pipe coupler, some epoxy, and some rough sandpaper (i got 60 grit). take apart your throttle housing (very easy, 3 bolts for the housing and an allen for the bar end, and if you cant figure this out, you shouldnt be messing with the throttle linkage to be honest)


first thing you do is cut off a piece of the pcv coupler that as wide as the white throttle cam on the handle. if its a little wider, thats fine. i used a hacksaw because at this point i been drinking for a good 4 hours, and using power tools would guarantee me to cut my hand off. besides, a hacksaw cuts thru pvc like hot knife thru butter


figure out how much of the pcv ring you need to cut out to make it fit over the throttle cam. doesnt have to be perfect, as long as you can wrap the leftover of the pcv ring over the throttle cam


cut out the piece of the pcv that you dont need, then grab a file/dremel/whatever and taper down the 2 new ends. dont have to taper them down to an edge, just get them close. by now, if you didnt see how this would work, you should


now grab your sandpaper and sand the outside of the throttle cam and inside of the pcv. its essential that this joint is glued very good, because if the pcv ring comes off, if could jam the throttle open and you could die so scuff up both glued surface real good, grab your epoxy, mix it up and glue the pcv ring to the outside of the throttle cam. make sure its lined up good with the back side of the throttle cam (youll file off the shit sticking out past the front in the next step). clean up the excess epoxy with a paper towel and let it sit for however long it says.


after its dry, grab your file and file away the pcv thats sticking out over the edge. then with your hacksaw and a thin file, cut a new groove for the throttle cable in the pcv ring. i cut mine deep enough to have just about the entire cable buried in the groove, the stock groove is pretty deep


last step is to make sure it fits in your throttle housing and doesnt bind up. theres a notch in there that stops the throttle from going all the way around, but you dont want it binding up at all anywhere else, once again, the throttle could jam open and you could die.


reassemble the throttle housing, set your throttle cable slack and your done. enjoy your snappier throttle that you dont need to regrip anymore. take it easy til you get used it it, if you crash and die because you went wide open accidentaly, power wheelied, looped and died, its not my fault.


Original Posting:
http://www.r6-forum.com/forums/showthread.php?t=125767

[dmyers]

Cool!!

[blowndodge]

we used to use Zip ties around the throttle housing as a quick cheap faster throttle.

[Duff]

Alright, tackled this tonight. The 1" is indeed perfect to fit around the throttle cam, however the outer diameter is too big for the switch housing. But simple enough to fix by grinding a little off. If you go too far, you've still got plenty of PVC to start over.

Overall cost was $7.49 for the 1" coupler and some Gorilla Epoxy at Ace Hardware.

I'll take it back off tomorrow and measure the ending thickness of the finished piece of PVC if I get a chance.

[Jared]

Originally Posted by Duff

Alright, tackled this tonight. The 1" is indeed perfect to fit around the throttle cam, however the outer diameter is too big for the switch housing. But simple enough to fix by grinding a little off. If you go too far, you've still got plenty of PVC to start over.

Overall cost was $7.49 for the 1" coupler and some Gorilla Epoxy at Ace Hardware.

I'll take it back off tomorrow and measure the ending thickness of the finished piece of PVC if I get a chance.

From what I've read, the outer diameter of the cam with the mod needs to be around 1.525" and the ring should only be 1/16" think. Much larger and it will rub.

$7.49....? You must have bought the fancy glue.

[dmyers]

I would also add
If you have a drimal tool with a sanding drum and cutter attachments the hole job is very easy

[Pitchinguy]

Like Duff said, the 1" pvc coupling is a perfect fit/curvature. When I did mine I also had to file a little off to keep from rubbing the rib in the inside switch housing. Didn't need much so I just used a coarse file. It's definitely a big improvement that takes the slop out of the low speed throttle. I didn't have that problem with my 1600 & wonder why Kaw goobered it up on the 1700s.

[Jared]

Originally Posted by Pitchinguy

Duff is right, the 1" pvc coupling is a perfect fit/curvature. When I did mine I also had to file a little off to keep from rubbing the rib in the inside switch housing. Didn't need much so I just used a coarse file. It's definitely a big improvement that takes the slop out of the low speed throttle. I didn't have that problem with my 1600 & wonder why Kaw goobered it up on the 1700s.

It gives you the "feeling" of more power on any bike, including the 1600.

If you don't want to worry about this mod at all, you could just turn the throttle quicker. It's essentially doing the same thing.

Here are some complete throttle tubes that already have a larger cam. I haven't looked for one that would fit my Kury grips or the Vulcan switch housing, but I'm sure there's one that would work just fine. Here a complete replacement throttle tube with a performance cam for only $10.99!

On the race track, this mods is very common. Racers don't turn their wrists fully to achieve full throttle. I've seen such large over size cams that with a 1/2" turn you are at full throttle. That large would definitely not be a good mod for a beginner.

You can also buy throttle tubes with removable/replaceable cams, depending on the type of riding you're going to be doing.







Or a simple zip-tie, as BD suggested works for many people.

[cactusjack]

Originally Posted by blowndodge

we used to use Zip ties around the throttle housing as a quick cheap faster throttle.

"CHEAP" being the key word here.

[dmyers]

the limiting factor on the vulcans is the housing
I rarely give my bike full throttle and i like the smooth power delivery that i get with the stock one when im hitting the twisty's it keeps the bike very smooth and planted out of the corners

[scottshaffer]

Originally Posted by Utah Motorcyclist

Here a complete replacement throttle tube with a performance cam for only $10.99!

It was closer to $109 with the three cams when I checked.

[Jared]

Originally Posted by scottshaffer

It was closer to $109 with the three cams when I checked.

Perhaps when buying all three cams... I wouldn't know, I've never bought one.

[Damo222]

Done the throttle mod today using a piece of 1" pvc pipe, very impressed by the difference it makes.
Thanks for the info.

[ringadingh]

I'm debating on whether I do it or not, I have a spare throttle tube so it may be a good project for a rainy day.

[blowndodge]

Originally Posted by cactusjack

"CHEAP" being the key word here.