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.............................................-- Throttle Linkage --.................
I was in for a surprise when I got to the throttle linkage. I hadn't been around bikes for a long time and the last time I was around them there was one throttle cable and a return spring. Now there are two cables and a spring. One cable pulls the throttle on and when you twist the grip back off the other cable pulls the throttle off. I guess this became a safety issue. I wanted to be able to use stock cables for the ease of switching from one motor to another, for example when I replace this 750cc Suzuki with the much larger Suzuki 'Busa motor. This meant I had to come up with a linkage system that would allow me to hook up both of the throttle cables. I just hope the cable ends are pretty standard on these engines.
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This is what I came up with. I started by making the two bushings above out of round stock. The "U" shaped piece with two holes in it will hold the other tow plates at the top of the picture. The center holes on both ends of those will trap the barrels on the ends of the throttle cables. The "U" piece will be welded to the long rod that is round stock drilled at one end and tapped for 1/4 inch rod that will go up to the gas pedal we made on the previous page.
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Bolts were welded to the two bushings with the tig welder.
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Then two holes were drilled in some flat strap and the bolts/bushings were inserted and bolted to it. The left arrow points to where the 1/4 rod going forward to the gas pedal will screw in. The other two arrows point to the holes that will hold the ends of the throttle cables. The bottom assemble and long rod will slide back and forth in the bushings. This all comes apart.
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Next the cable housing ends had to be secured so that the cable would pull back and forth. This is for one throttle cable and the big hole is so the rod can slide back and forth past it and the other hole with the slot is for the cable/cable end.
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It was welded to the upper piece on one end (the end towards the rear of the car).
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Here it is in place. A small hole was added to it for the small tab that keeps the cable end in the bracket. Now you can see how the barrels on the end of the cable are trapped.
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Next this piece was made for the return cable which had a different end on it requiring this bracket to be somewhat different to the one on the other end.
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It was also welded to the top bracket. The small "nail head" looking piece is so that a zip tie can be mounted to keep the cable in the slotted area.
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Here is the linkage almost done, except I had to have a way to mount it on the frame, so .............
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.................... made a top piece (two arrows) with a hole in it and welded it to the assembly and .............
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.................... mounted it with a bolt to the frame. The arrows point to the rod going forward to the gas pedal.
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Another view from the bottom with the rod (arrow) more visible. It works well, so I'm happy.
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