Changing throttle cables

[b1k3rdude]

"and am assuming there’s no way a changing them without carb removal."

Yes and no, you can do it in situ, but only have a set of thin long nose pliers with right angled tips and even then its a faff. Gnasher will correct me if my recollection is out of date.

From member the easiest way I have found is to follow the manual for the most part -

• Deinstall the throttle/choke cables from the switchgear (you need the slack on both)
  
• Remove the battery - creates space for airbox to move back into
  
• The manual says to loosen the airbox mounting bolts (but you can get a bit more movement by removing them) and then disconnect the hoses from the airbox etc. Then slide the airbox back as far as it will go
  
• What the manual fails to mention is there is a cable (Exup cables I think) on the right handside of the airbox that gets jammed between the airbox and the frame. Removing these would/should give 5-10mm more space for the airbox to move.
  
• I then use bungees to hold it there, then I undue all the air box clamps.
  
• Then remove the coolant/vacuum hoses from the carbs. Now the manual says to remove the TPS from the carbs but if your carefull you can leave in-place. Otherwise use tipex to mark the position on the mounting bolts before removing the TPS.
  
• Then loosen all the inlet manifold and airbox boot clamps
  

And at this point is where I have deviated, as it makes getting the carb out/in so much easier  -

• I removed the airbox cover and air filter (this allows you to reinstall the air-box boots from the inside etc)
  
• I then do up the airbox boot clamps just enough to grip the boots (you don't have to do this, it just fitted my workflow)
  
• I then pushed all the airbox boots into the airbox. With these out of the way the carbs require no wiggling to remove from the bike, as you will have an extra 2-3cm free space behind them.
  
• Make sure to place some protection over the engine and frame to protect them from scratches/scuffs from the carbs while you remove the throttle cables (ask me how I know)
  
• Then replace the throttle cables and then re-install the carbs back into the inlet manifold rubbers and do the clamps up.
  
• Then re-attached all the hoses and choke cable if you removed it.
  
• Then the reverse of steps 3,2 & 1 - and regarding putting the boots back, I suggest spraying some GT85 on the rear parts that fit into the airbox holes as this makes putting them back in so.... much eaiser.
  

The biggest single issue I and other owners have had is that the airbox dosen't seem to or cannot go back far enough, which is why I came up with the above work around with the air-box boots.