[Smidge]

Ok guys im losing my mind here. I had problem at the carb which was making the throttle not return properly. Got that all fixed and buttoned up. But now I'm having issues with the throttle sticking still.
I've installed BRAND NEW cables, and can't get any freeplay in my throttle... .at first it would only stick when turned full right or left. Now it sticks everywhere.
I've tried loosening the bolts for throttle housing (this helped a bit but still binds at full left/right)
Lubed the cables
Rerouted cables
Messed with the adjustments (the screw on carb and throttle ends is completely screwed in) all I can do is increase tension. I'm never getting MORE freeplay.
It I remove the entire throttle assembly from the handlebar, throttle operating works just fine.

[JimDirt]

OK , if you are not having a issue with it removed , then I would guess that either when you are tightening the throttle up you are binding it , or you are putting it too far into the bar and do not have any side to side movement ..... when assembling the throttle , you don't need to torque it down , you just need the screws tight enough to not allow the throttle assembly to spin back and forth on the bars ......

What I would try is make sure that the cables are not hanging up on the white plastic guide , it is easy for the cable to go over the lip and it will bind as soon as you tighten things down

Then I would also take the cable adjuster on the carb , and the one with the locknut , loosen all the way , till the adjustable part is all the way to the locknut , with no threads showing , this is the first step to getting slack .... next go to the throttle assembly , and do the same thing screw in the one with the locknut , you should not have plenty of freeplay .....

Where I route the throttle cables is right between the right radiator and the frame , right at the mount , now make double sure that when you have it go under the tank , that the tank is not resting on the cable , it should move back/forth freely with no resistance .......

Tighten the throttle assembly just enough so the gap is even on both sides , then slightly tighten each one till it snugs up to the bar and you can grab the throttle and twist hard and it does not move ... if it does , slightly tighten the bolts till it is solid

If after this , there is too much slack , then tighten the adjuster on the throttle assembly only , not at the carb , snap the throttle a few times , it should snap back , do it at both extreme left and right , it should not slow down , it should still snap back


Report back with results ....

[Smidge]

OK , if you are not having a issue with it removed , then I would guess that either when you are tightening the throttle up you are binding it , or you are putting it too far into the bar and do not have any side to side movement ..... when assembling the throttle , you don't need to torque it down , you just need the screws tight enough to not allow the throttle assembly to spin back and forth on the bars ......

What I would try is make sure that the cables are not hanging up on the white plastic guide , it is easy for the cable to go over the lip and it will bind as soon as you tighten things down

Then I would also take the cable adjuster on the carb , and the one with the locknut , loosen all the way , till the adjustable part is all the way to the locknut , with no threads showing , this is the first step to getting slack .... next go to the throttle assembly , and do the same thing screw in the one with the locknut , you should not have plenty of freeplay .....

Where I route the throttle cables is right between the right radiator and the frame , right at the mount , now make double sure that when you have it go under the tank , that the tank is not resting on the cable , it should move back/forth freely with no resistance .......

Tighten the throttle assembly just enough so the gap is even on both sides , then slightly tighten each one till it snugs up to the bar and you can grab the throttle and twist hard and it does not move ... if it does , slightly tighten the bolts till it is solid

If after this , there is too much slack , then tighten the adjuster on the throttle assembly only , not at the carb , snap the throttle a few times , it should snap back , do it at both extreme left and right , it should not slow down , it should still snap back


Report back with results ....

I tried all of this yesterday. Both adjusters carb and throttle side were screwed all the way in (no threads showing) one in and one out, both out, etc. All I was able to do was reduce freeplay and make the throttle tighter/worse.
I ended up taking the motion pro cables off and comparing them to some oem ones. The motion pro cables ended up being about 2" longer than oem. I put oem back on and everything worked just fine.

The motion pro cables have the correct part #on the package for my application according to their website and a few other websites.

I'm sticking with oem for now and have ordered a new set of the oem ones.

[JimDirt]

Actually you did not mention that the "new" cables were not OEM ..... and yea , I have had issues with Motion Pro on my 02 , kind of the same thing , except the issue with mine was the cable housing was thicker than OEM and it kept pinching the cable when the tank was installed and making it bind up , but remove the tank and all was well , ended up going with OEM and all was good , but I was "assuming" you were installing new OEM parts ....so yea , that would be the issue ..... I guess I should have asked if they were aftermarket or not ... my bad ....... I have found that with Fork Seals and Throttle Cables , OEM is best and seems to last longer .. as well as fit better ...

Glad you got it sorted out ....