Looking at my five year old and sticky feeling gas pedal throttle wire, i thought of making one shorty version instead of this "tour around" the engine bay one :D



i found a new replacement part from a nearby local auto parts store for $14.6.



it's part number as a reference.



after few minutes of inspection, i then cut the pedal end's stopper thinking that i'm going to shorten it's overall length anyway.



Wondering on how to secure the wire's end later, i then bought this cable locks from a nearby local bike parts store for 2 cents each.



after cutting the wire's end stopper and test fitting the bike's brake wire lock, pull out the wire from the assembly and safely hang it somewhere so it won't get soiled. I found a nice wooden hanger laying around my garage so it was just perfect! LOL!



next step was to cut the the wire's spiral steel sleeve right at the tip of firewall mounted plastic lock/molding feed through.





as you can see, part of the spiral steel sleeve is still present inside the plastic molding...



using a 4mm drill bit, i then slowly inserted my electrical drill and manually rotate the chunk. NO, i did NOT turn on the drill as it might break the plastic molding when at high speed/normal drill operation. simply rotate it patiently, clock wise about 5mm deep and do a counter clockwise spin after. it will then pull out that left over spiral piece off the plastic molding.



using a 6mm drill bit this time, slowly rotate the bit through the molding and carefully remove the rest of the remaining part of the sleeve, enlarging it so you can re-insert the entire spiral steel sleeve, making it well secured plus a clean looking finish.





i then mounted the sleeve into it's location on top the intake manifold and marked it's length as per my preference...



cut through your mark...



deburred the end using a fine file...



i had to transfer few old parts of my previous throttle cable into the new one as it didn't posses them. plastic lock, rubber bump and washer.



while i didn't have any glue/epoxy sealant around, i then used a self sealing heat shrink tubing...







of course it's always necessary to re-adjust your cable assembly, mount it with proper slack not to cause binding when on/off your throttle pedal.



shrink the wire's end not to cause fraying later on...



the throttle pedal feels snappy :D

 

Enginuity......lol. My head gasket blew yesterday and was thinking the same thing about the throttle wire while taking the head off. Nice write up bro!!!

 

excellent writeup!