snapped throttle cable... needs replacing!!!

[chadwick]

Hi

After sorting the electrics fault on my Honda CG125, (thanks for the help guys-a new battery was all it needed) the throttle cable decided to snap just after starting the bike at work today.
Odd because on pulling half the broken piece through the sheath it appears the cable was not rusted or worn-just decided to snap!...

Anyway it seems the cable operates two bits on the carb, a plunger into the top of the carb and a cam on the side, it is the cable that pulls the plunger up on top of the carb that has snapped. Any advice on replacing it-seems a fiddly job- and do you have to rebalance the two cables etc- might be one for a garage I think?

Cheers,
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Chadwick

[mchaggis]

Disassembling a single CG125 carburettor is not really such a challenging task. A socket set and a set of screwdrivers will be enough. Giving it to a shop to do would be pouring money down the drain.

Seat, side panels and tank off and you should be able to see enough to unscrew the fcap with the cable from the top of the carb. I can't remember exactly the cable mechanism for the accelerator pump, but it is pretty foolproof. Just make sure that you remember where things went and it isn't difficult. The spring is a bit of a pain to reseat with the cam, but everything can only go on one way, or it won't work. The cable should just fit.

The cap on top is holding a slide (housing the main needle) , held to it by the throttle cable with a spring between them. Normally it would all just lift out, but if the cable is broken it probably won't. If that is the case, you'll have to remove the carb and tip it out. Unclamping the airbox and undoing the nuts holding the carb to the inlet rubber isn't difficult.

Edit: I forgot to mention the throttle grip end. You'll want to unscrew the RHS switch gear halves (well, mirror and brake lever mount on an older model) after you have disconnected the bottom end of the cable. The throttle tube should then slide off the grip and you can remove and replace the top end of the cable. Cleaning and lubricating the bar and inside of the throttle tube might well be a good idea.

When you remove the cable, get a piece of sturdy string, tie one end to the frame by the carb and the other end to the bottom end of the cable. Pulling through the cable from the top will make sure you know the path it went through before. Putting it along the same path as the original is important.

After you've finished, make sure the idle speed does not change as you turn the bars and that the new cable isn't trapped or kinked.
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