Throttle Cable Sticks

[expat1]

Hey....I have an 89 Sammy and my old throttle cable was fraying at the firewall by the black cap. I replaced the cable and it worked fine for a short time. It became more and more "sticky" the more I stepped on the gas until it felt like it would literally snap almost feels like the cable is "grinding" somewhere. I thought it might be a defective cable so I replaced it a second time. It worked fine for a short time too. Now this one is getting harder and harder to use too. The pedal is fine...spring etc. no binding. The carb seems to be okay too....can use hand to turn accelerator manually. What could be causing it to bind up?? Seemed okay prior to replacing old cable...no binding...just sticky due to fraying wires...not retracting quickly from the broken strands. Carb is new 6 mos. Tranny replaced last week...works fine. Can't figure this out for the life of me.

[Billjohn]

Try using some powdered graphite.

[Merlin93]

Originally Posted by expat1

... my old throttle cable was fraying at the firewall by the black cap. I replaced the cable and it worked fine for a short time. ...

That's where mine (and everyone else's) seems to break. When installing the new one, I use a liquid graphite suspension called "Lock-Ease, Graphited Lock Fluid". It commonly comes in a 3 oz. blue & white can with a short red snorkel. I hold the cable vertically, and introduce the liquid at the top until it runs out the bottom. The petroleum solvent/carrier liquid evaporates, leaving the graphite inside the cable jacket. 40+ years ago in Africa I used it regularly to keep my motorcycle cables clean and lubed, while everyone around me was breaking theirs. I've been using it ever since. There's lots of cable-operated gizmos where "Lock-Ease" can be used -- works on locks as well!

Billjohn's right -- Graphite's the answer to this one.

[expat1]

Well thanks you tweo for the suggestions........Up here in the "Great White North" the closest thing to the suggested graphite is Jig-A-Loo" graphite lubricant in a can....Sales guy was trying to sell me some "Oily" crap......."NO!!!...I WANT A DRY LUBRICANT"!!!!....Anyway....Shoved the little tube up the hole and sprayed till it was done. Worked the cable through until well covered.....and reinstalled. Definitley loosened things up nicely however it still feels like it wants to bind up a bit...BUT I will give it a bit of time and see if it works its way though from there......If not....any other suggestions if needed???

[Billjohn]

The only other suggestion I would have is to look again at how it is connecting through the firewall. Is it hanging there? Or seated firmly.

[Merlin93]

Originally Posted by expat1

... Up here in the "Great White North" the closest thing to the suggested graphite is Jig-A-Loo" graphite lubricant in a can....

The Canadian Tire on Veterans Blvd. should have Jig-a-Loo Graphite. I've not used it, but it seems like a good choice.

One possibility is that a bend has caused the unlubricated cable to wear through the liner inside the outer cable housing. My cable has to make an S-bend to reach the throttle plate. I re-routed the cable, trying to make the bends as gentle as possible. I covered the outer cable with a section of rubber fuel-line hose to further protect it as it snakes its way through the engine compartment. [My last cable broke about 6 miles back off the road in Death Valley. Not a place to be walking out of. ]

Edit: 28Sep09 Bought a can of Jig-a-Loo at Home Depot today. It has a much heavier consistency (a lot less liquid carrier vehicle) than Lock Ease, but leaves a smooth, rather thick graphite coating over everything. I lubricated the pivot on an old set of garden shears that had gotten hard to use. I'll keep it in my arsenal. And my Samurai passed Calif. Smog! Whoopee!

[expat1]

Yeah...The Canadian Tire is just around the corner from Death Valley...Picked some up yesterday....The "Little Boot" at the firewall is seated properly and there is a gradual "S" bend in the cable......Just a note...the cable(s) were unused new so they should not have binded at all...but I soaked them through, from each end, and will recoat them again this week. Is funny cuz this had not occurred at all in 7 years and with new carb (6mos) the linkage should be fine.....Mind you.....the cable frayed AFTER the new carb was installed so maybe something in the linkage is lurking somwhere and hides when I look for it......Steps were as follows for new cable..... The cable should loop in the cab to gas pedal thru firewall (pop boot in place)........no sharp bends to throttle......loop other end UNDER the pin-thingy place and hook up in place.....set "elbow" into connector thingy and snug in place with nuts....with cable just taut enough to not "play" or too tight....Hit with hammer several times to make sure nothing is loose <grin>..... Very straight forward.......We shall see.....Thanks you two for the assistance....TTYL

[expat1]

Well....after all this......I have the "FINAL" solution to my dilemma.

The solution is......DO NOT BUY REPLACEMENT PARTS FROM NAPA!!!!

Two cables later with no resolution...I called Suzuki directly and had them order in a Real Suzuki Throttle cable. Not an aftermarket piece of junk!!!!

I switched out the cable and nearly put my foot through the floorboards cuz it was so EASY to do . Thank goodness this isn't a 300hp engine or I'd be outta here

So FYI....DO NOT use any cables from NAPA with a part prefix.....ALT
And specifically the throttle cable NAPA part number ALT 1503601.

It is poop!!!!!

So thanks for the imput guys.....Seeya next time when the next fixit is needed.

[Billjohn]

The one thing we always assume is that a new part is perfect... it is (after all) something that should be taken for granted. But it can bite us on the butt sometimes. Lesson learned. Thanks for the warnng.
Glad you got everything working.