Sportster 1200: Little-by-Little Changes

 
Used condition ★
This ↑ is the “stopper not engaging” state.
Because the stopper isn’t engaging, the play is maintained by the tension of the OPEN/CLOSE cable.
It has a squishy, mushy feel.
 
The stopper bolt has been swapped for a flush bolt & threaded into the throttle side,
so we’ll skip the lock nut.
The bolt gets about 5mm shorter, and we save weight from the nut.
Now the stopper engages, so you get a nice click when you release the throttle!
The stopper works properly and closes firmly—it really feels solid. Play is also easier to adjust.
Here’s how the stock setup looks.
 
The return side is in bad shape—risky.
The mounting position is way off, putting serious strain on the cable.
If you install it without checking inside the throttle body—just “sure, sure”—and there’s no stopper,
and you adjust a long throttle inner cable by feel,
you can end up with a cable in trouble, so please be careful.
 
One more thing: with these big throttles, even at full open, the stopper might not make contact—that’s something to watch for too.
Though I doubt it’ll happen in most cases…
By the way, the throttle hasn’t been cleaned yet ★

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