Well related to Carburetors - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 3 (permalink) Old 4-1-2019, 8:05 PM Thread Starter
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Location: Chamblee GA
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Well related to Carburetors

My Throttle cable on my 2006 EX500D has an issue. The place that the cable screws into the housing at the handle bars is broken, Still works just the threaded part that screws in the housing on the handle bars is broken.

I have replacement cables and understand the handle bar housing (or I think I do :-) ) but looking at the carburetors or I should say looking down between the two carbs, it does not seem real obvious if I can get the cables off and replaced on the carbs without pulling the carbs. On my Honda shadow, the throttle cables on the side not in between.

And speaking of the carbs to pull them off do you have to pull the air box back or can you get them out with messing with the air box?

I am looking at the Haynes Kawasaki 87 to 08 and on 4-9 it says Detach the decelerator and accelerator cables from the throttle pulley at the carburetor assemble (see Chapter 1, section 1

But when I look at Chapter 1, section 18 it discusses Throttle cable adjustment at the carbs (if you adjust them at the grip end) but I don't see squat about just removing the cables for replacement.

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post #2 of 3 (permalink) Old 4-1-2019, 9:53 PM
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Location: Atlanta,GA
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You can remove the cables without removing the carbs, but it is very difficult to do, and even more difficult to put the new ones on like that. It is much easier to do with the carbs removed. You would have to loosen the air box and move it towards the back to gain enough room to remove the carbs.
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2006 Ninja500R Purchased new July 2006; 0 miles. Miles as of January 2019; 102,137. It's a GO bike, not a SHOW bike.
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post #3 of 3 (permalink) Old 4-2-2019, 12:10 AM Thread Starter
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Thanks for the reply. Well might hold off a bit to put in the new throttle cables. Guess if I got that far might as well do a carb job at the same time. Maybe something to do latter this summer.

I guess it is not that major of a job, to pull the carbs and I not sure why I am feeling a bit of trepidation at the job but I guess because my last and first Carb rebuild job did not go as smoothly . I mean not bad but just a few bumps in the road. Guess at some point you got to get back on the horse.


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