How to Assemble Scooter Throttles

All motorcycles from vintage to modern use a throttle cable system to activate more gas flow.

Putting together a scooter throttle depends on learning only a few symbol needs. Once accounted for, a throttle system can be constructed and made effective. A builder just needs to understand that the throttle needs to be activated by the hand or foot via cable to the carburetor. Once pulled, the carburetor opens up allow more gas into the engine.

Things You'll Need

• Screwdrivers
• Cable housing
• Throttle cable
• Pulleys
• Carburetor
• Grease
• Power drill

Instructions

Preparation and Assembly

1. Use a screwdriver and open up the scooter headset so that the handles are exposed. Find the end of the right handle inside the headset. Locate cable pulley and put it on the end. Drill a small hole through the pulley and the handle if it's not already there. Place a cotter pin through the hole so the pulley stays on the handle. Put a notch in the pulley as big as the end of the throttle cable with the lead plug on it.

2. Slip the throttle cable into the pulley notch. Grab the cable housing and run it down into the headset neck, into the scooter body and out towards the engine carburetor. Line up the engine side of the cable housing with the carburetor cable intake. Take the other end of the throttle cable and insert it into the installed housing after greasing the entire cable. Push it all the way through until the small end goes out of the housing on the engine side.

3. Take the engine side of the throttle cable and connect it to the carburetor slide inside the carburetor. Use a screwdriver to access the slide assembly inside. Close the carburetor up once connected. Test the throttle cable system by twisting the throttle handle. Make sure the cable pulls as the pulley twists with the handle. Remove any slack in the cable if found and reconnect it to the carburetor. Test again until the cable is snug and reacts to every twist by pulling on the carburetor slide.

4. Turn the scooter engine on and let it idle to warm up. Test the throttle cable by twisting it to confirm it works. Listen for fuel to be added to the engine as it revs up with the throttle twist. Get on the scooter, put it into gear, and twist the throttle to test it works and accelerates the scooter. Take the scooter for a test ride.

Tips & Warnings

• If the engine side of the cable doesn't have a lead tip on it to connect to the carburetor, you can manufacture a homemade connector using a small pinch bolt. Slide it onto the cable, screw it tight to pinch the cable where you want it, and then connect it to the carburetor slide mechanism.

• Always make sure to grease the throttle cable as you insert it into the throttle housing. Otherwise it can form friction spots and the cable will eventually fray and break.

References

• Scooter School: Replacing Throttle Grip on a Scooter
• I Scoot NY: Frequently Asked Questions
• Youtube: How to Install a Throttle Cable Into a Carburetor (video)

Resources

• Monster Scooter Parts: Throttle Cables
• Scooter Parts 4 Less: Gas Scooter Parts