How to Install a 90cc Baja Dirt Bike's Throttle Cable


Although those little red and white dirt bikes sold at many home improvement stores look like toys, Baja Motorsport's Dirt Runner 90 dirt bikes can move quicker than you'd think. These 90cc dirt bikes are controlled by a steel cable attached to the right handlebar's twist grip to open and close the throttle. However, many of these are not assembled by the seller, leaving it up the owner, to finish the task. Installing the cable is not difficult and can be done with common tools, but take your time to do it right.

Things You'll Need

  • Phillips screwdriver
  • Throttle cable
  • 10 mm wrench
  • Remove the screws from the bottom of the throttle housing on the right handlebar using a Phillips screwdriver. Separate the upper and lower halves from around the twist grip.

  • Slide the throttle cable's barrel-shaped catch into the tube on the upper half of the throttle housing. Push the cable inward until the threaded portion of the cable's sleeve contacts the housing.

  • Twist the outer sleeve clockwise to screw the cable into the throttle housing. Stop when the lock nut on the sleeve is flush with the throttle housing. Insert the cable's catch into the indent on the edge of the twist grip.

  • Place both halves of the throttle housing over the twist grip. Insert the housing's screws and tighten them, using a Phillips screwdriver.

  • Route the throttle cable around the left side of the front fork and under the fuel tank. Push the cable through the frame until it protrudes above the carburetor, positioned under the seat and fuel tank.

  • Unscrew the round cap from the top of the carburetor by hand. Screw the end of the throttle cable into the cap and pull the cable's end to extend the cable.

  • Slip the cable's end into the indent on the throttle slide within the top of the carburetor. Screw the carburetor's cap into place by hand.

  • Twist the handlebar-end of the throttle cable counterclockwise to tighten the cable slightly. Twist the twist grip to check the cable's tension. Ideally, the grip should move at least 1/8-inch before it pulls the cable. Loosen or tighten the cable as needed.

  • Tighten the lock nuts on both ends of the throttle cable against the throttle housing and the carburetor, using a 10 mm wrench.

Related Searches


  • "The Professional Motorcycle Repair Program"; Professional Career Development Institute; 1995
  • "Baja Dirt Runner 90 Owner's Manual"; Baja Motorsports; 2009
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