Hey everyone,
I used the information from the following post to make this mod on two '05 ZX-6R race bikes, and it works great:
http://www.kawiforums.com/showthread.php?t=118250
I've taken his instructions, and modified them to fit my pictures
Things you need:
1" SCED40 PVC fitting. I used a union, which gave me two true ends to cut off.
5 min epoxy
Sander: I used my belt sander. I dremel would work as well.
![Image]()
1. I used a small band saw to cut the end off the fitting, about 1/16th inch wider than the width of the throttle cam.
![Image]()
2. Cut about 5/8" out of the PVC loop.
![Image]()
This will allow the PVC to snap over the throttle cam
![Image]()
3. Shape the ends of the PVC with sand paper, or a belt sander, so that they taper smoothly for the cable. This will also give you clearance for the metal tabs that can cause interference in the throttle housing.
![Image]()
4. Sand and clean the throttle tube cam, and the inside of the PVC. This will prepare the plastic for the glue.
5. Using 5 minute epoxy, or an equivilent, glue the PVC onto the throttle cam. IMPORTANT! You have a cut side, and an uncut side to your PVC. The uncut side is true and smooth. When you glue it to the cam, make sure the uncut side is in the inside of the cam, and does not overlap the cam at all. Make sure there is no glue left to harden on the inside. It must be smooth, or it will bind in the housing. You should see your excess PVC hanging on the outside of the cam.
![Image]()
6. After the glue hardens, sand the outside of the cam so that the PVC and the cam surface are perfectly smooth. If the PVC overhangs the cam, it will bind in the housing.
7. As and option, you can remove the small metal tabs in the cable housing that might bind on the PVC. I did not do this. Instead, I installed the unit and twisted the throttle several times. It was evedent were these tabs were binding on the PVC. I sanded the PVC until clearance was obtained.
8. Lightly grease everything, install the throttle tube with slack cables, readjust and check for binding. CHECK FOR BINDING!!!
This picture shows the difference with the PVC installed. The idle mark in on top of the throttle, and not visible. The lower mark is where the throttle rotated without the PVC. This picture shows WOT with the PVC.
![Image]()
Be careful, and do this mod at your own risk.
I used the information from the following post to make this mod on two '05 ZX-6R race bikes, and it works great:
http://www.kawiforums.com/showthread.php?t=118250
I've taken his instructions, and modified them to fit my pictures
Things you need:
1" SCED40 PVC fitting. I used a union, which gave me two true ends to cut off.
5 min epoxy
Sander: I used my belt sander. I dremel would work as well.
1. I used a small band saw to cut the end off the fitting, about 1/16th inch wider than the width of the throttle cam.
2. Cut about 5/8" out of the PVC loop.
This will allow the PVC to snap over the throttle cam
3. Shape the ends of the PVC with sand paper, or a belt sander, so that they taper smoothly for the cable. This will also give you clearance for the metal tabs that can cause interference in the throttle housing.
4. Sand and clean the throttle tube cam, and the inside of the PVC. This will prepare the plastic for the glue.
5. Using 5 minute epoxy, or an equivilent, glue the PVC onto the throttle cam. IMPORTANT! You have a cut side, and an uncut side to your PVC. The uncut side is true and smooth. When you glue it to the cam, make sure the uncut side is in the inside of the cam, and does not overlap the cam at all. Make sure there is no glue left to harden on the inside. It must be smooth, or it will bind in the housing. You should see your excess PVC hanging on the outside of the cam.
6. After the glue hardens, sand the outside of the cam so that the PVC and the cam surface are perfectly smooth. If the PVC overhangs the cam, it will bind in the housing.
7. As and option, you can remove the small metal tabs in the cable housing that might bind on the PVC. I did not do this. Instead, I installed the unit and twisted the throttle several times. It was evedent were these tabs were binding on the PVC. I sanded the PVC until clearance was obtained.
8. Lightly grease everything, install the throttle tube with slack cables, readjust and check for binding. CHECK FOR BINDING!!!
This picture shows the difference with the PVC installed. The idle mark in on top of the throttle, and not visible. The lower mark is where the throttle rotated without the PVC. This picture shows WOT with the PVC.
Be careful, and do this mod at your own risk.
