Replacement throttle cable

Taffy · Mar 26, 2017

OK, I'm on it! we just got those throttle housings and Julia didn't check that a cable would fit but because we have another one here we should sort it quickly. can you send it back to us? we can pay your postage but please send it via USPS and slow and cheap.

regards

Taffy

Taffy · Mar 27, 2017

hello

julia here .. we are going to sort this just bare with us.. we have to measure the thread and find out if our supplier has them or has to make them or have them made... we are gonig to "play" around in the workshop and test a few things to see if it works.
my question to you is does the cable fit into the carb ?
the only thing wrong with the cable is the thread size? is this correct

many thanks
julia

bholmes · Jun 10, 2017

Taffy said:
hello

julia here .. we are going to sort this just bare with us.. we have to measure the thread and find out if our supplier has them or has to make them or have them made... we are gonig to "play" around in the workshop and test a few things to see if it works.
my question to you is does the cable fit into the carb ?
the only thing wrong with the cable is the thread size? is this correct

many thanks
julia

Sorry I haven't replied, but life finally slowed down recently. The cable you sent is perfect except for the threads at the handlebar end. I went to a local hardware store to confirm the thread size. I need a throttle cable with M8 x 1.25 thread. You sent one with M10 x 1.25 thread. Let me know how to get reimbursed for shipping this cable back to you.

bholmes · Jun 11, 2017

Taffy · Jun 12, 2017

Hello

If you are happy with the total length of the cable
if you are happy with the excess of wire out of the cable
if you are happy with the nipple and adjustment to fit the mikuni
if you're happy with the barrel nipple at the throttle end

....then I would be sorely tempted to change the throttle assembly to a Domino from 99-03
or
to file all the thread away and get down to 8mm diameter and put a tap on it.

but your problem is at the HANDLEBAR end and not the carb end which is where we thought you'd have trouble!

ho-hum!!!!!

Taffy

bholmes · Jun 12, 2017

Taffy said:
Hello

If you are happy with the total length of the cable
if you are happy with the excess of wire out of the cable
if you are happy with the nipple and adjustment to fit the mikuni
if you're happy with the barrel nipple at the throttle end

....then I would be sorely tempted to change the throttle assembly to a Domino from 99-03
or
to file all the thread away and get down to 8mm diameter and put a tap on it.

but your problem is at the HANDLEBAR end and not the carb end which is where we thought you'd have trouble!

ho-hum!!!!!

Taffy

All of the above are true. The barrel at the handlebar end may be too large to fit an 8mm die over it, and it is definitely too large to fit a new 8 mm nut over it. If it were fashioned with a gap or split (similar to a cable pull brake on a mountain bike) then it could slide over the cable below the barrel.

Taffy · Jun 12, 2017

then get a domino throttle for it which was the OEM item anyway!

you can take a little off the corners off the barrel nipple to make it all work.

Taffy

bholmes · Jun 22, 2017

Tell me where I can find the domino throttle cable

VOR165 · Jun 22, 2017

He said throttle, not cable.

The cable you received is the correct one, if your bike is 100% original. The problem is you do not have the original throttle housing, i.e., the twist grip, that came on the bike from the factory.

The throttle from an 08 KTM 200 xc-w should be the same as the original domino throttle that came on your bike from the factory. Its $47 from Rocky Mtn Atv.

bholmes · Jun 23, 2017

I have a domino throttle on it, but it's not the oem based on the parts catalog, so I'm lost as far as what to do now. I'm likely to make another $50 purchase that leaves me still without a working throttle.

bholmes · Jun 23, 2017

I can't find the 99-03 cable you mentioned, either.

bholmes · Jul 15, 2017

Ended up taking it to a local machine shop, cost $10 to rethread it down to 8mm diameter. Works like a charm.

Taffy · Jul 16, 2017

Taffy said:
....then I would be sorely tempted to change the throttle assembly to a Domino from 99-03
or
to file all the thread away and get down to 8mm diameter and put a tap on it.

Taffy

good thinking Batman!!!

Julia and I are perplexed as to why it happened. lack of info and lots of fog mean we give up!

regards

taffy

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