Removal and disassembly
Warning! To prevent spray of fuel, purge system of high-pressure fuel before supply line is disconnected. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury.
1. Purge the fuel supply hose of high pressure gasoline. Disconnect fuel supply hose from fuel pump module. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
2. Remove main fuse.
3. Remove seat.
4. Remove fuel tank. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
5. XL Models:
- a. See Figure 2-174. Remove screw (3) securing left wire harness caddy (2) to right wire harness caddy (1). See 6.28 ELECTRICAL CADDIES. Separate left wire harness caddy from right wire harness caddy.
- b. Cut cable straps (5) securing throttle cables (4) to right wire harness caddy. Remove and discard cable straps.
- c. Disengage ignition coil bracket (6) uprights from frame bosses and remove throttle cables from recess in right wire harness caddy.
Figure 2-174. Wire harness caddy assembly: XL models: 1. Right wire harness caddy; 2. Left wire harness caddy; 3. Screw; 4. Throttle cables; 5. Cable straps; 6. Ignition coil bracket
6. See Figure 2-175. Slide rubber boot off each cable adjuster (4).
Figure 2-175. Throttle control, right handlebar: 1. Ferrule (2); 2. Throttle control cable assembly; 3. Idle control cable assembly; 4. Cable adjuster (2); 5. Spring; 6. Retaining ring; 7. Screw (2); 8. Friction spring; 9. Upper housing; 10. Handlebar; 11. Lower housing; 12. Throttle control grip; 13. Throttle friction screw; 14. Throttle cable clip; 15. Throttle retaining ring; 16. Idle retaining ring
7. See Figure 2-176. Loosen jamnut (5) on each adjuster (6). Turn adjusters in direction which will shorten cable housings to minimum length.
Figure 2-176. Throttle/idle control cable (typical): 1. Throttle control grip; 2. Throttle friction screw; 3. Idle control (pull-close) cable; 4. Throttle control (pull-open) cable; 5. Jamnut (2); 6. Cable adjuster (2); 7. Throttle cam; 8. Cam stop; 9. Idle control cable guide (on throttle body); 10. Throttle control cable guide (on throttle body)
8. See Figure 2-175. Remove two screws (7) and separate upper housing (9) from lower housing (11).
9. Unhook ferrules (1) and cables (2, 3) from throttle control grip (12) and lower housing (11).
10. XR 1200X: See Figure 2-178. Disengage cables from retainer (2) on lower fork bracket. Disengage cables from loop retainer (3) located under fuel tank.
11. Remove air cleaner assembly. See 4.3 AIR CLEANER ASSEMBLY, XL Models except XL 1200V, 4.3 AIR CLEANER ASSEMBLY, XL 1200V or 4.3 AIR CLEANER ASSEMBLY, XR 1200X.
12. Disconnect cables from induction module.
13. See Figure 2-175. Remove friction spring (8), throttle friction screw (13) and spring (5) from lower housing.
Cleaning and inspection
Warning! Compressed air can pierce the skin and flying debris from compressed air could cause serious eye injury. Wear safety glasses when working with compressed air. Never use your hand to check for air leaks or to determine air flow rates.
Clean all parts in a non-flammable cleaning solvent. Blow dry with low pressure compressed air. Replace cables if necessary.
Assembly and installation
| FASTENER | TORQUE VALUE | |
| Switch housing screw | 35-45 in·lbs | 4.0-5.1 Nm |
1. See Figure 2-175. Apply a light coating of graphite to the handlebar (10) and the inside surface of the upper and lower housings (9, 11).
2. Install spring (5), throttle friction screw (13) and friction spring (8) in lower housing (11).
3. Attach cable assemblies (2, 3) to lower housing. See Figure 2-176. Throttle control cable (4) has a 5/16 in (7.9 mm) fitting end and is positioned to front oflower housing. Idle control cable (3) has a 1/4 in (6.3 mm) fitting end and is positioned to rear of lower housing.
4. See Figure 2-175. Connect cables:
- a. Install throttle control grip (12) over end of right handlebar (10).
- b. Position lower housing (11) onto right handlebar, engaging lower housing with throttle control grip.
- c. Position ferrules (1) over cable ball ends.
- d. Seat ferrules (with cables attached) in their respective notches ofthe throttle control grip.
5. Install upper housing (9) over handlebar. Install the lower housing using screws (7). Tighten to 35-45 in·lbs (4.0-5.1 Nm).
6. XL Models: See Figure 2-177. Route the cables:
- a. Point the cables forward from the throttle control grip and the front fork upper bracket.
- b. Turn the cables downward between right slider tube and headlamp.
- c. Route the cables rearward along right side of frame steering head and frame backbone.
- d. Turn the cables over the ignition switch housing.
- e. Pass the cables between the coil bracket and frame.
- f. Route the cables downward to the induction module.
Figure 2-177. Throttle control cable routing: XL models
7. XR 1200X: See Figure 2-178. Route the cables:
- a. Route the cables forward between right fork and brake hose (1).
- b. Turn the cables back between the forks above the lower fork bracket.
- c. Pass the cables through the wire retainer (2) on the lower fork.
- d. Route the cables above the front cylinder toward the induction module.
Figure 2-178. Throttle control cable routing: XR 1200X: 1. Brake hose; 2. Wire retainer; 3. Loop retainer
8. See Figure 2-176. Install idle control cable (3) housing into inboard (idle) cable guide (9) on induction module.
9. Install throttle control cable (4) housing and spring into outboard cable guide (10) on induction module.
Note. The forward cable strap secures the instrument connector [20]. The rear cable strap secures wiring harnesses on other side of caddy wall.
10. XL Models: See Figure 2-174. Place throttle cables (4) into channel in right wire harness caddy (1). Secure with two cable straps (5).
Warning! Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury.
11. XL Models: See Figure 2-174. Mount left wire harness caddy (2) to right wire harness caddy (1). Secure with screw (3) and tighten.
- a. Do not pinch the cables between the frame and/or forks.
- b. Verify that the cables do not pull tight when the handlebar is turned full lock left and right.
12. Adjust control cables. See 1.13 THROTTLE CONTROL, Cable Adjustment.
13. Install air cleaner assembly.
14. Install fuel tank and connect fuel hose. See 4.4 FUEL TANK: XL MODELS or 4.5 FUEL TANK: XR 1200X.
15. XR 1200X: See Figure 2-178. Secure cables in loop retainer (3). Attach retainerto the bottom ofthe fuel tank.
Warning! After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury.
16. Install seat.
17. Install main fuse.