How to: Make a 1/5 turn throttle

Posted this up in the MN.

This modification will make it so you do not have to turn the throttle as much to get the throttle all the way open. This is so that you do not have to reposition your hand on the throttle to open it all the way. It is very useful to those who ride on the track.

A little warning about this modification.
This WILL make the throttle more sensitive. You will not have to open it as much to get the same amount of power as the stock throttle.

Things you need:
PVC pipe - 1 1/4 in
Dremel
Throttle off of your bike or a new one
Some type of glue (I used Loctite Super Glue)
Some sandpaper

This was done on a 2004 R6.

The unmodified stock throttle should open this much to get WOT.




First, go to any hardware store that sells PVC pipe and have them cut you a small piece of 1 1/4in pipe.



Remove your throttle from your bike. When doing the rest of this modification, I found it easier to detach the brake lever and right side ram air cover so they don't get in the way.
Now put the PVC pipe up against the throttle and mark where you want to cut it.



Cut the piece of pipe where you marked it at and slide it on the throttle tube.



Cut it some more if you have to to make sure the piece of pipe seats properly around the tube.

Now take it off the throttle, and using the dremel, round off the edges of the piece pipe. It should end up looking something like this.



Use some glue and glue it onto the pipe. You can use some sand paper to smooth it out if you want to.
--Make sure that the PVC pipe is not wider then the part of the tube you are glueing it to. If it is then it will rub against the housing and prevent the throttle from snapping back.--

Take the throttle housing off the clip on and remove the throttle lines from the housing. You're going to have to grind down the metal throttle line tubes so that they don't rub against the PVC. You will also need to grind down some parts inside the throttle housing itself. I've circled the parts that I grinded down using a dremel. (sorry that it is a little blurry)



Now you will have to loosen the throttle cable as much as possible. Here is the page from the service manual that explains how to do it.



Once it is loosened, you can now put the throttle back in.
Once you have it in, play around with it making sure that it is not rubbing anywhere. Turn the handle bars all the way to the left and right. When the handles bars are all the way to either side, rotate the throttle and let it go. It should snap back to its closed position. If it doesn't, then you may have to grind down some more parts because something is rubbing somewhere.

This is how much your throttle should turn when you are complete with this project.

nice write up, any problems with this setup, it looks to be a CONSIDERABLE difference in throttle movement for full power. any way this could be changed to reduce it to about half of the original throttle movement needed? also any idea how this would work with an 06-08 since the throttle is different on those models? once again great write up though.

Originally Posted by PepeRB29

nice write up, any problems with this setup, it looks to be a CONSIDERABLE difference in throttle movement for full power. any way this could be changed to reduce it to about half of the original throttle movement needed? also any idea how this would work with an 06-08 since the throttle is different on those models? once again great write up though.

I honestly wouldn't know how to make the throttle turn that short without buying an aftermarket throttle. You can only make it the circumference so wide that if you go anywider you wouldn't be able to turn it without some more modification to the housing. This set up for me is perfect. If it was just half it would be too touchy IMO.

As for the 06-08 question, I have no idea. Have never seen one open. Just open it up and see if it might be possible.

Thw question I have for you is this. In the parts list you say to use 1 1/4 inch pvc but in the pic showing the pvc cut you say to use 1 3/8 inch. Wich one?

Yea, my bad. I copy and pasted this How To I wrote for the MN orignially. There I originately posted that I used 1 3/8in PVC pipe. But everyone was saying that they couldn't find that size. Another member said he used 1 1/4 in pipe and it worked out for him. So I changed it this time around to say 1 1/4in since it seems that it was easier to find. I'd change it if the edit button was available, but its not right now.

K thanks

Pepe, the answer to your question is that the more you cut away from the PVC the more throttle play you'll still have. its pretty much changing the ration of the throttle. think about it like this, one chain and two different sized sprockets. the bigger sprocket doesnt have to move as much to move the chain X amount of links where as the smaller sprocket will have to make more rotations to move the chain the same amount of links. know what i mean?

so if you cut double the amount from the PVC you should have 1/10th more throttle play than john has in his new throttle. in theory

but to make it have half the original throttle movement you would need the same inner diameter PVC, but it would have to be thicker, and pretty much just trial and error that shit. but you might run into problems with the cable rubbing on the inside of the throttle housing...

Man, i thought a 1/4 turn throttle was twitchy! Who's using this setup and why?

After looking at the prices for some aftermarket throttles out there, I'm seriously considering giving this a try this spring...