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XP THROTTLE CABLE REPLACEMENT... I WONDER WHAT BOOK TIME IS ON THIS?

mountainhorse

mountainhorse

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I just got finished installing a throttle cable for a friend on his 2010 XP 800 163" summit X....

REALLY???:loco::loco:

Remove console, gauge pod, rear chassis support, fuel tank, Secondary clutch and belt, rear airbox, carburetors, Reed boot, fuel pump and then getting your hands down on the oil pump pivot to remove the snap rings/cable etc... then put the whole thing back together.

I'm sure an experienced mechanic knows how to cuts some time out of the process.

I'm wondering what "Book Rate" is for replacement of the trottle cable assembly on these sleds?
 
badass1000 and Pyxle... Thank you for the information.

How long did it take you to do the job?

I'd like to see ANYONE (single person) that can do the job in 1 hour... Crazy!!

How do you get access/room-to-work with the fuel tank in place?

Removing the boots Reeds really did not free up any space for me as the reed boss' on the cylinders overhang quite a bit... moving the fuel pump did help considerably though.
 
It definatly is a pain in the ***. I bet if a guy did it a lot he could get it in an hr, but the average garage guy? more like 4 and a six pack. I pulled the carbs, boots, and reeds, then ended up getting a stiff wire like a coat hanger, hook it and pull it wide open and tie it off somehow by bending the other end around something. once its open you can fish it in there but not without loosing some skin! this worked for me, but it was definetly tight. I'm pretty sure everyone has to go through it at least once with so many cables out there fraying.
 
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Where do they start to fray?
Like how do you know when you need to be changing it?
 
Mafesto said:
Where do they start to fray?
Like how do you know when you need to be changing it?
Click to expand...

I actually broke my throttle cable right at the carbs, but that was my fault from putting it in a bind when jetting. I was glad it happened though cuz when I tore it apart I saw it was fraying right above oil pump. I looked around on here after it happened and saw a few others had the same problem.
 
one up ya

I have to... I rebuilt my motor due to the failed cable and forgot to bleed my pump. So I get to take it all the way back down again to prime oil lookin for a good time
 
I would guess that they are good for 2400 km or 1500 miles. Just did one the other day at 2300 km and it was starting to fray at the oil pump end. This is the 4th cable that we have done this year in a group of 6. Some have frayed at the throttle end but all show significant wear at the oil pump end.

They are disposable, just accept it and replace it before it wrecks your day/week/month or year.

I am around 4hrs at changing one out not tilting the motor. Can't wait to own an etech so i can lose this job.
 
there must be a reason they are coming apart,,,, you would think. i dont want to replace one every year
 
Service manual tells you to lift the engine, they have a lifting eye that screws into one of the spark plug holes. this allows you to lift the motor enough to get to the pump without dissconnecting any of the wiring or hoses. It is possible to do it in 1 hour, but everything better go smooth. I allways remove the secondary clutch and tower brace and get it out of the way. remove the carbs and the fuel pump. then take the motor mount bolts out and lift the motor so you can get at the oil pump.

I made a lifting eye out of an old compression tester adapter and a eye bolt. and a lifting arm out of some mild tube steel. you can buy the tools from brp but these were made out of scrap laying around my shop.

DSC04883.JPG DSC04886.JPG DSC04885.JPG
 
Did mine about 2 weeks ago. I took my secondart tower off also, lot easier to work. never did roll the motor forward. Ended up threading the cable thourgh the pto side motor mount to get hooked to the oil pump. Thats what i struggled with. Took me at least 3 hours and a lot of curse words/ and dips. ha.
 
heres a suggestion. Delete the oil pump and premix. Makes life easy as pie to change the cable then. !0 min. tops. Just my .02. 900 miles on mine premixing and motor still like new!
 
All I got to say is check it! 536 miles an 23 hours mine broke at the lever, ball end was still in the handle cable was loose! An it ONLY happened on a 50 degree SUNNY (i was in a t shirt) day w/ 2' of fresh! Dealer started at 9 am an was finished at 4! Lots of cursing, an it looked like the whole sled was apart!
 
my cable frayed at the oil pump right at the begining of my third year on my 08 xp. bought it brand new dec 07. I actually just put the turbo system on and thought something was causing run on from the turbo. Got to really looking at it and noticed the throttle cable was all frayed and hanging up. I just had every thing all apart and did not notice it. It takes me a little longer because of all the stuff associated with the turbo set up. so I would guess it would take me 3 hours or so to change it.
I really did not want to pay the $75 brp charges for a throttle cable. the oil pump is the same part number for the revs. I ordered a spi throttle cable for like a 06 ski doo summit. $17. It worked just fine. Oil pump side was a little shorter. I just routed it a little different. throttle side was a couple inches longer. still went in great just routed the oil pump side a little different. Still have the spi cable on it now and it works fine.
I believe ski doo changed the oil pump attachment on the 09's. I am not positive though. The older 06 cable may work and it may not. RSI offers a longer cable. it is listed as 8" longer though. Longer then I need. the 06 summit cable at 2" longer is great.
 
Last edited:
Rode on Friday, just happend to look at the cable, had only 2 strands holding it to the lever. Had to turn around and head out.
 
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