Need 5th Gen Favor

I still haven't found the solution to my throttle cable problem (see posted titled "'00 Throttle Cable Question"). I've rechecked the helibar instructions and the cables are routed exactly as described. Could someone who has helibars on their 5th gen and who does not experience the kinking on the left side as per my post please send me a picture showing how you have your cable routed?

If you can't get the throttle positioned correctly, it is most likely that you have the bars backwards. I know. I did it. Swap left for right and you will be amazed. The throttle body will click into place easily. Trust me.

To verify the correct orientation, check that the clamping hardware is inserted opposite the way the stock hardware was. It is counter-intuitive, I know.

Here is a picture from my completed installation last year. It doesn't show the cable routing but it does show the overall orientation of the bars. Note the hardware on the top, Heli logo on the bottom. Otherwise, I followed the installation instructions for routing of the cables. Good luck.



[image: heli.jpg]

Romy, Apr 8 2007, 12:38 AMHere is a picture from my completed installation last year. It doesn't show the cable routing but it does show the overall orientation of the bars. Note the hardware on the top, Heli logo on the bottom. Otherwise, I followed the installation instructions for routing of the cables. Good luck.

Thanks for the pic. Like your grips by the way.

I wish I could take a picture of what the problem is. I can tell by the responses I've received that I'm not explaining it well.

The Helis are installed as per installation instructions. And yes, the left bar is on the left and the right is on the right. When installing I removed the top of the triple clamp and re-routed the throttle cables so that they are behind the right fork tube. The cables aren't too short. It's almost as if they're too long.

Picture looking down on the left side to where the throttle cables disappear through the gray plastic and into the engine compartment. As I turn the bars counterclockwise, the cable (where it meets the gray plastic on the left side) moves over to the far left side. As the bars continue to move counterclockwise, the left fork tube contacts the throttle cable (remember that the cable where it goes into the engine compartment has moved to the left). At full lock the cable/gray plastic intersection is to the left of the fork tube and the tube has pressed the throttle cable back toward the engine. The result is a very sharp kink in the throttle cable at that point.

mick, Apr 7 2007, 11:51 PM

Romy, Apr 8 2007, 12:38 AMHere is a picture from my completed installation last year. It doesn't show the cable routing but it does show the overall orientation of the bars. Note the hardware on the top, Heli logo on the bottom. Otherwise, I followed the installation instructions for routing of the cables. Good luck.

Thanks for the pic. Like your grips by the way.

I wish I could take a picture of what the problem is. I can tell by the responses I've received that I'm not explaining it well.

The Helis are installed as per installation instructions. And yes, the left bar is on the left and the right is on the right. When installing I removed the top of the triple clamp and re-routed the throttle cables so that they are behind the right fork tube. The cables aren't too short. It's almost as if they're too long.

Picture looking down on the left side to where the throttle cables disappear through the gray plastic and into the engine compartment. As I turn the bars counterclockwise, the cable (where it meets the gray plastic on the left side) moves over to the far left side. As the bars continue to move counterclockwise, the left fork tube contacts the throttle cable (remember that the cable where it goes into the engine compartment has moved to the left). At full lock the cable/gray plastic intersection is to the left of the fork tube and the tube has pressed the throttle cable back toward the engine. The result is a very sharp kink in the throttle cable at that point.

That's odd. The only other thing I can suggest is that I didn't replace the OEM cable tie that went around the fork. I left the cables free once I routed them behind the fork. They seemed to be naturally routed that way. I would get you some updated photos but my digital camera is on loan to friends traveling in Hawaii. Good luck.

As for the grips, I like the feel of them. The Pro Grip 719 was certainly an upgrade from stock. My only complaint: they are impossible to keep looking like new. They get grubby looking and are nearly impossible to keep bright. I don't know if I would go with the yellow if I had to do it over again.

The only thing I can think of is that maybe the throttle cables are routed around the wrong side of the fork tubes? Here are a couple pics which show how mine are routed on my 2000. It's a little tough to see, but you can see the throttle cables go inside of the left fork tube and out side the right fork tube. These pics were taken with my steering at the (left) lock position.

Good luck and I hope this helps.

[image: gallery_1904_2145_52178.jpg]
heli cables 2

[image: gallery_1904_2145_138338.jpg]
heli cables 1

You can see the throttle cables in the first pic directly below the tube with the writing on it, and you can see they go inside the fork tube.

Lobster, Apr 8 2007, 06:14 PMThe only thing I can think of is that maybe the throttle cables are routed around the wrong side of the fork tubes? <SNIP> You can see the throttle cables in the first pic directly below the tube with the writing on it, and you can see they go inside the fork tube.

Thanks for the pics.

They were routed exactly as you show... behind the left fork tube (stock configuration) and behind the right fork tube (a modified position as per Heli instructions).

Out of exasperation, I removed my Helis this morning and put the stockers back on. No kinking whatsoever! I'll leave the stock ones on until I can figure out what was wrong. I need to be able to look at someone's Heli clad, 5th gen Viffer to discover the source of my problem. Don't see very many down here at all but hopefully I'll bump into somone before long.

I put heli-bars on 2 years ago, and I recall fussing with my throttle cables for awhile, and removing the factory cable ties as Romy did and leaving things fairly free. I'm away from the bike right now, but I will try to shoot some photos tomorrow when I'm home in an attempt to add to what's already here.

One other great thing to do when mounting heli-bars is to cut the locator tabs off the brake and clutch master cylinders where the hose attaches. This allows you to rotate the levers down so that your wrist is nearly straight when working the brake and/or clutch. Easy to do with a die grinder (after a few deep breaths). Cut away the tabs, slightly loosen the banjo bolts, move the levers down and rotate the hoses so they clear the top of fork tubes again. Move the hoses and levers a little at a time until you get them where you want them. I'll try to shoot a photo of that, too.

Good luck,
Keith

Here are three photos I shot this evening. It looks like I have the same layout as Lobster showed. I tried to shoot really clear pictures with enough in there that you can see where the cables run. I'm not sure this adds anything to what has already been presented here, but maybe it will be of service to you.

I tried to get pictures of the how I cut the hose locator tabs off the clutch and brake cylinders to rotate the levers down, but just couldn't get a good angle. But it should be obvious what to cut away.

Throttle cables go in front of the right fork tube, electricals go behind (note how the brake lever is rotated down):
[image: gallery_3463_423_80947.jpg]
Throttle side

[image: gallery_3463_423_45387.jpg]
From above

Throttle cables run behind the left tube and to the rear. The cables aren't attached to anything, as they were with the stock bars, they are left to slide freely as the bars turn side-to-side:
[image: gallery_3463_423_127579.jpg]
From clutch side

Keith

keithbob, Apr 10 2007, 02:21 AMHere are three photos I shot this evening. It looks like I have the same layout as Lobster showed. I tried to shoot really clear pictures with enough in there that you can see where the cables run. I'm not sure this adds anything to what has already been presented here, but maybe it will be of service to you.

Thank you, Thank you, Keith. I think I see now what the problem is. Remember in my post that I said I installed the Helis as per instructions? Here's a cut and paste of the instructions about routing the throttle cables:

"4. The throttle cables need to be moved behind the right fork tube and must remain on top of the right control�s wire loom and the ignition switch wire loom."

Notice it says BEHIND the right fork tube. If you'll look at your photo (below), it clearly shows that you have yours in front. This explains why I said that it was almost as if the cables were too long. If you're not having any problem with kinking, it means Heli's instructions are off. Here's your pic below that shows it:

[image: gallery_3463_423_80947.jpg]
Throttle side

I tried to get pictures of the how I cut the hose locator tabs off the clutch and brake cylinders to rotate the levers down, but just couldn't get a good angle.

Not to worry. I did this already. I VERY carefully did it with a dremel tool.


Thanks a bunch Keith.... and everyone else that helped out with this problem.

Did you mean the electrics or the actual actuating cable? I thought you meant the actuating cable, and I think you're referring to the electrics, which is clearly a different animal.

Anyway, glad it worked out.

mick, Apr 9 2007, 08:27 PM"4. The throttle cables need to be moved behind the right fork tube and must remain on top of the right control�s wire loom and the ignition switch wire loom."

Notice it says BEHIND the right fork tube. If you'll look at your photo (below), it clearly shows that you have yours in front. This explains why I said that it was almost as if the cables were too long. If you're not having any problem with kinking, it means Heli's instructions are off.

After thinking about it, I seem to remember futzing around quite a bit with cable and electrical routing, and I think I tried following those directions and deciding it wasn't going to work. I do remember it took all afternoon to get things on and working right.

Anyway, you'll be a LOT more comfortable riding now. I clearly remeber thinking "They want how much for those?!!" and balking for a while, then taking the plunge. Boy, am I glad I did. 500+ mile days are a pleasure now.

Enjoy!

keithbob, Apr 10 2007, 08:51 AMAnyway, you'll be a LOT more comfortable riding now. I clearly remeber thinking "They want how much for those?!!" and balking for a while, then taking the plunge.

You should have seen the battle inside my cranium, screwing up the courage to hacksaw apart a brand new set of Ducati 900SS Helibars for my front end project!
unsure.gif comp13.gif huh.gif sad.gif ohmy.gif dry.gif


But in the end, it was all good!