Throttle Cable - To replace or no?

[Teej83]

I managed to break the fancy new polaris throttle block when i flipped the boost trying to whip it out of a hole. One nice palm slap on **** plastic was all it took.

Luckily a few zips ties saved what turned out to be an epic weekend.

But i did notice the cable itself got a bit marred. Looks a little gnarly in some photos, not bad in others. i assume it got kinked and the coating scarred when the thumb throttle broke free. cut in coating looks fairly deep.

All that said - what’s the consensus? Replace cable - which looks like a major pita? or continue to send it and monitor? kink is next to where it hooks to thumb throttle so absolutely no impact on throttle movement or sticking.

 

[RBalazs]

I’d replace it and I tried finding one of the new 2025 ones and there’s not any in the country. They’re all back ordered.

 

[turboless terry]

My buddy just broke his 25 throttle block.

 

[Teej83]

My buddy just broke his 25 throttle block.

Better design but poor quality. The plastic around the metal pin is pretty weak

 

[Pickin’ Boogers]

Replace it. Pull the tank and it’s not that bad - worse than previous models but still doable.

 

[turboless terry]

Better design but poor quality. The plastic around the metal pin is pretty weak

Seems that way. It held cobbled up through his trip. He couldn't find one at local dealerships. He ordered a munster when he got home.

 

[RBalazs]

My buddy just broke his 25 throttle block.

Well, I run a Munster finger throttle so I won’t break the throw the block

 

[Teej83]

Replace it. Pull the tank and it’s not that bad - worse than previous models but still doable.

Alright so pull the tank, did you pull the boost box also from the TB’s or can you access it after removing tank and airbox? Guess i know how my afternoon will be today

 

[RBalazs]

Alright so pull the tank, did you pull the boost box also from the TB’s or can you access it after removing tank and airbox? Guess i know how my afternoon will be today

Correct. Pull the tank, pull the boost box and there the cable connects right to the throttle body connects. My buddy over, tightened his throttle cable when screwing it into the throttle body and snapped it off and had to get a second cable. So just be careful when you’re screwing that in. It does seem like it was a poorly cast piece of aluminum, but regardless it was still an issue.

Actually, I forgot, but here is a video my buddy did of him and I replacing his on his boost.

 

[Teej83]

Correct. Pull the tank, pull the boost box and there the cable connects right to the throttle body connects. My buddy over, tightened his throttle cable when screwing it into the throttle body and snapped it off and had to get a second cable. So just be careful when you’re screwing that in. It does seem like it was a poorly cast piece of aluminum, but regardless it was still an issue.

Actually, I forgot, but here is a video my buddy did of him and I replacing his on his boost.

Watched that one - pretty hilarious

 

[Pickin’ Boogers]

Yeah, it's tedious and absurd how many different fittings and parts need to be removed for a simple cable replacement. But there's nothing difficult about it - no special tools, no flipping the sled over, no need to hook up to a laptop, etc.

 

[HECKS]

I've snapped that cable too. That nut is 5 Nm for torque after I looked it up in the service manual.

 

[Teej83]

My dumbass shot the little throttle cable c clip off into the engine bay somewhere. Compressor inlet was open, so I get to shoot some air into that tomorrow to make sure its clear. Fun times

Rest of the job was straightforward though