How to Replace & Install a Throttle Cable on a Motorcycle

Like any other cable on your motorbike, over time your throttle cable will stretch, wear, fray and corrode. At Venhill we have been making replacement cables for more than 50 years and here is our guide on how to replace and install a throttle cable on a motorcycle.

Your owner’s manual will usually provide some guidance on how and when to check the condition of your throttle cable - how often will depend on the make and model as well as how, when and where you ride - but it’s well worth getting into the habit of giving your cables a quick once-over before every ride and a more detailed inspection before longer journeys. Here’s how: 

Visual Inspection

First, a quick visual inspection along the length of the throttle cable can uncover any obvious issues like cracks or kinks in the conduit (the cable’s outer covering), corrosion at the exposed ends of the inner wire, and anything untoward with nipples and other fixings. 

Throttle Cable Free Play

Next check the ‘free play’. Free play refers to the amount of rotation your throttle travels before it starts pulling on the cable. To measure it, make a note of the grip position with the throttle fully closed, then slowly twist the throttle open until you start to feel the tension in the cable. The distance from the ‘closed’ position to the tension point is the free play.

Most manufacturers specify 2-3mm of free play for the throttle to respond correctly and accelerate smoothly. A cable that’s too loose will give poor throttle response, one that’s too tight can result in a high engine idle speed and a sharp, sensitive throttle action. 

Incorrect cable free play doesn’t usually require replacement of the cable, it can be adjusted. Read our Expert Advice Blog on why and how you should adjust your bike’s throttle cable.

Throttle Return

Finally, check throttle return by turning the twistgrip all the way open, then letting it go. If the twistgrip doesn’t ‘snap back’ to the closed position, it indicates there’s a problem with either the routing of the cable or damage to the inner wire.

How to replace a motorcycle throttle cable in 10 steps

If your bike’s throttle cable does require replacement, it isn’t a particularly difficult or technical job, but as with any other component on a motorcycle it needs to be done correctly. If you’re confident taking the job on yourself, here’s how to do it in 10 steps.

Before starting, make sure the bike is secured on a centre or paddock stand, and there’s plenty of space and light to work with. Replacing a control cable doesn’t normally require many tools, but you may need to loosen or remove components and bodywork for access, and remove cable ties. You may also need some light oil (WD-40 or 3-in-1 etc) to loosen fixings and lubricate your new cable, so have this all within easy reach.  

1. Locate the cable you wish to change and remove any components or bodywork that will stop you from accessing or changing it. This will vary depending on the bike and how the cable is routed; you may only need to remove small items like an engine cover, or larger parts like the seat or fuel tank.
2. Next, make a note of the routing of the original cable, so you have a record of how it runs around the frame, forks and other components. If you don’t have a good memory, draw it out or take pictures with your smartphone.
3. Check that the new cable matches the old one; the outer needs to be the same length and diameter; have any brackets/gromets in the same places; and the nipples/barrels that connect the cable to the components at each end need to match too.  The distance the inner cable sticks out at either end also needs to be the same. Don’t worry if there's a slight difference, (maybe a couple of millimetres), because the old cable may have stretched over time.
4. Next, disconnect each end of the cable. At the handlebar lever or brake pedal you should find an adjuster screw and lock nut that holds the cable in place. Loosen both and align the openings so the cable can be removed from the lever/pedal. Do the same thing at the clutch or brake drum/calliper end, and then check along the length of the cable for any brackets or cable ties that might prevent it being removed.
5. There’s one last job before installation; hold the replacement cable vertically and use a few drops of a light oil to lubricate the inner wire, moving it up and down to ease the oil down the inside. If you’re fitting PTFE 'teflon' lined cables, like Venhill Featherlight, you won’t need to do this, because they’re designed to operate smoothly over their lifetime with minimal lubrication.
6. You’re now ready to route the new cable. We suggest leaving the original cable in place, if there’s enough space, so you simply feed the new one along its length. Make sure the cable will comfortably reach its intended connection at either end. Then remove the old one. If there isn’t room to do this, it’s sometimes possible to attach the new cable to one end of the old one with strong duct tape or string, and then gently pull through until the old one is out and the new one is in its place - make sure you get the new cable the right way round.
7. Once the cable is in place, check along its length for contact with sources of heat, such as cylinder heads and radiators - allow a suitable gap between them. Reattach any brackets or grommets and if you’re using cable ties, remember to leave them loose so that the inner wire isn’t squashed and can move freely, take care not to clamp the cable too tightly in place, as it can restrict the handlebars or controls from moving freely.
8. Then reattach the inner cable to each end - step four in reverse. Where nipples/barrels require lubrication in levers or linkages, use a small amount of silicone cable grease. Avoid using heavy greases, as they attract dirt and can restrict movement.
9. Set the cable adjustment or free play as per your motorcycle manufacturer’s guidelines and operate the lever/pedal to make sure it’s working freely. Most modern bikes have Push-Pull throttle cables and with this design it's essential to connect and adjust the pull cable - which opens the throttle - first.
10. Finally, check the handlebars turn lock-to-lock feely, and that the cable operates at both extremes of steering. If you can’t turn the bars fully or the cable doesn’t operate properly, check the cable routing, looking for pinch points or areas where it may have slipped out of place. Also, check adjusters and that all the nipples are located properly.

[Note: Always consult your motorcycle’s service/owner’s manual before adjusting or replacing any component on your motorcycle. If you’re not 100% confident doing any of the steps above yourself, consult a professional.]

Buy High Quality Motorcycle Throttle Cables from Venhill

We recommend upgrading to our Featherlight Throttle Cables, which are developed from the original factory-fitted lines, and are designed to give improved performance and feel, as well as adding durability and a smoother action.

You can find throttle cables for most makes and models of motorcycle in our part finder. If your bike isn’t listed, we can make cables to almost any specification with our Bespoke Cable Service. 

And finally, in this short video we explain the basics of replacing a motorcycle throttle cable.