SOLVED: Helibars throttle binding

[dem]

Alright, I'm baffled.. my 2014 came with the HeliBar riser plate installed by the PO, it seems to be installed correctly (throttle cables routed behind ABS/hydraulic cables) yet I am getting binding on full left lock.

Even weirder, I tried changing the HeliBar setting to "widest" (ie, loosest cable position) and it still binds.

Did the cables get shorter in 2014? I am stumped, but obviously this is no good.

[raYzerman]

The cables are different for Gen3 fly by wire, but I had to reroute mine... inboard side of the brake lines... you have to disconnect them at the handlebar, push them back into the engine compartment and slip them back up through... got a pic of current routing?

[bill lumberg]

First, check what is binding. That’ll help determine what they didn’t install correctly.

I had the same problem with helis on my 2014. The cables had not been moved around the brake block (where the lines are all together). So even though everything had been disconnected and rerouted during installation, (the hard part), we hadn’t situated them exactly correctly (the easy part). Once I had done that (which was in the instructions, I just didn’t realize it), there was no binding. There will be no binding, lock to lock, in any handlebar adjustment position, when things are adjusted properly.

In my case, nothing had to be disconnected to fix the oversight. I only had to give slack by turning the bars, and grab the lines and direct them around the line block. Then everything was perfect.

On my 2018, I did this on install and had no issues.

[dem]

They just seem too short - at full lock they get pulled tight and bind at the grip end (the angle gets super sharp on exit) and they will bind wrapping over the bridge when pulled tight. I disconnected them at the throttle end to play around. If I screw in the tension adjuster all the way, that gives a bit of relief, same if I adjust the bars forward all the way (still binds, but not as much.) Basically it looks like I need another half inch of cable.

What happens to the throttle cables after they go under the tank? Any way something could interfere with them there if they are routed wrong or something?

Routing:

[raYzerman]

The routing in that pic looks right to me (if that is factory, then my mistooken comments, bad memory).... under the tank the cables go into a loop on the right side of the T-bar then straight to the TB's.... nothing much you can do there

[Uncle Hud]

Have you checked the grip itself for binding? Could the throttle position sensor cause this?

If the cables are loose and you still get binding ... then the cables aren't the problem.

[dem]

Have you checked the grip itself for binding? Could the throttle position sensor cause this?

If the cables are loose and you still get binding ... then the cables aren't the problem.

Yes, I have disconnected the cables.. the grip is fine, and when non-binded, the cables move freely.

I guess I'll give Helibars a call and see if they have any ideas.

[dem]

The routing in that pic looks right to me (if that is factory, then my mistooken comments, bad memory).... under the tank the cables go into a loop on the right side of the T-bar then straight to the TB's.... nothing much you can do there

Hm, I might try poking around under there. The PO had done some wiring loom surgery and I was under there to undo it, maybe I squished something?

[D-Eagle]

I had the same issue on my 2014. Thought I did everything according to instructions but at absolute full turn (I think left) I couldn't move the throttle at handlebar anymore. I moved the hoses around (and other hoses) and it created enough room to eliminate the issue. I did NOT disconnect anything again. I just moved the hoses around on how they were positioned on top of each other going down the neck and it made a difference.

[bill lumberg]

It’s eerie to see you describe exactly what I did on my 2014. I was visualizing my ‘14 while reading your post Deagle.

[raYzerman]

I think that's what to do also..... sure look under the tank to see if you can squeeze another 1/4" but.... perhaps a pic zoomed out a bit so we can see the hose/cable arrangement on that right handlebar and below......

[dem]

Well you guys gave enough clue.. I lifted up the tank and followed around the throttle cables - I had them routed on the "wrong" side of the "T" bar.

Moved them over and ta-da, all good.

Thanks for getting my brain going.

[wheatonFJR]

I love happy endings.

[jwilly]

You will always remember the day you started listening to advice from these bunch of goons..

[wheatonFJR]

You will always remember the day you started listening to advice from these bunch of goons..

I remember when all of a sudden threads started appearing with the words, "2013 FJR" in them. My friends helped me out of the hospital bed and into the seat of a bike...literally bringing it a thousand miles to my garage. I definitely remember the day...some crazies in this thread are the worst.

[bill lumberg]

That’s terrific. Excellent.

Well you guys gave enough clue.. I lifted up the tank and followed around the throttle cables - I had them routed on the "wrong" side of the "T" bar.

Moved them over and ta-da, all good.

Thanks for getting my brain going.

[bill lumberg]

Fool. There are cameras in that place.

I love happy endings.