Reassembly sequence 93 voyager carbs

[grumpy72]

I had to cut one cable down by the carb. I vould not get the ball end out of the housing. It is the one exiting the makeup box. I do have the do it yourself repair ki which includes more ball ends and a cable.BUT the other cable doesnt go through a box.its straightforward.goes from the handlebars snakes around, connects to a carb. I still dont know which is accel and decel.the picture in the manual indicates at handlebar level which is which.. BUT, does the cable i cut which exits the box, is that some sort of 2 piece thing? From the handlebar to the box is one piece and from the bottom of the box is the second half? It looks like i will have to remove the battery tray to see what I am doing.i have just about dissasembled the bike. A big challenge.

[Nails]

Yikes -- cut the cable?!?! These pups are hard to find!

And honestly, putting it on is more difficult than taking it off. You can gorilla on it to get it off, bending the inner cable and such. But getting it back on requires a crap-ton of patience and dexterity, along with a large roach clip (I mean hemostat). For me, anyway.

Since you reference cable fabrication, I gather you've seen the discussion in "Throttle cable splitter/junction box question". But that thread would seem to answer your question: the cable from the grip to the carbs is for deceleration. (Just twist the throttle up, and you'll see it pull.) The other cables are for acceleration.

[GrandpaDenny]

Another possible way to tell which is the deceleration cable is that it goes vertically up from the carbs, and should be tight - it shouldn't ever be slack, unlike the acceleration cable, which is slack at idle position.

[grumpy72]

Thank you denny. Mine is a 93 and has the box that a cable goes into and one coming out of it to a carburetor.like maybe #2 carb. The other cable starts at the handlebar and goes straight to a carb, no box. Maybe #3 carb. I had to cut the cable down by the carb. The whole thing at the handlebar end was crammed in the slot, frayed, crimped. I will have to replace the whole thing. I so far cant see how the box and cable are attached. I hope by removing the battery tray i can see more what I am needing to do.what a pain this is.

[GrandpaDenny]

Thank you denny. Mine is a 93 and has the box that a cable goes into and one coming out of it to a carburetor.like maybe #2 carb. The other cable starts at the handlebar and goes straight to a carb, no box. Maybe #3 carb. I had to cut the cable down by the carb. The whole thing at the handlebar end was crammed in the slot, frayed, crimped. I will have to replace the whole thing. I so far cant see how the box and cable are attached. I hope by removing the battery tray i can see more what I am needing to do.what a pain this is.

Oh wow I thought you'd had the battery tray out. No wonder you think it's such a kronk to work on. Take the battery tray out and the cable junction box will be sitting right there easy to get to. When you have it exposed, you will see three cables connected to it - one goes to the handlebar throttle, one goes to the cruise control, um, thingie (I forget what it's called) inside the right upper fairing, and one goes to the carbs. You will also see TWO other cables further to the right, one is the throttle decel cable, one is the starter (choke) cable.

Cables, cables everywhere! LOL.

[grumpy72]

I had to completely remove the mickeymouse cruise control box.the cable going into it was intact.that ball end drops into a hole on a roung springtensioned white piece of plastic. Junk in my opinion. The second half is about 18 inches or so.one ball end goes into a second hole on the round plastic junk thing.it exits out with its cable and its other ball end connects to the carbs. Not sure if its carb 2 or 3. The other cable at the handlebars is normal.one end connects inside the throttle sleeve at the handlebars the other to a carb. I think #3. The choke cable hoiks to #4. One of the cruise controlcable, a second cable, screws onto a nox inside the fairing. A wire goes from it to the dash. Probably says cruise on, off, set, resume etc. The colored wires from cruise control box probably go to the things behind the headlight.4 of them i think.called relays i think. One is for cruise, dont know or care which. The spring under the white plastic piece of junk came unraveled. Whoever messed with this bike before really did a number on it. Inside the plastic housing where the ball end of all this cruise junk fits was so mangled even with the housing in my hand, the cable completely loose and pulling on it with needlenose it wont come out.its like someone held a lighter to it to make it tighter. So now i will need a throttle sleeve. I in the automotive world did rings rod bearngs mains on a 327 and 350 chevy, straight 6 235, slant six 225, ford 289,302, and replaced head gaskers and cylinder base gaskets on a suzuki gs 1000. This is harder. I am going back together cruiseless. Using 2 normal cables. And i will attach them to the carbs, then push the carbs onto the head, then route the cables to the handlebar housing. One cable, the normal one, is completely intact. I appreciate the help. What a pain.

[grumpy72]

I am glad i finally reached a conclusion. I will make a new cable,use the old sleeve even though its in 2 pieces. I found a replacement cable for $10. If its the right length i dont have to make anything.wait till my friend gets the carbs done.hook the cables to them.push them back onto the head.shoehorn the airbox on.get the wretched springs back in place. Connect the choke cable, fuel and vacuum lines.slide the gastank back in.connect the filter. Hopefully it will start. It did before. I have never adjusted a cable before. I guess turn the adjuster till the slack is out, tighten the lock nut.see if the throttle opens right, snaps back when i let go of it. Then i have to replace both tires, get all the air out of the brakes, drill out the broken upper shock bolt and replace.remount the rear frame. I wanted to remove the upper fairing but I cant. Too many wires. But the fairing pieces with the pockets to help secure the fairing are either broken like the right side or completely missing like on the left side. I need both left and right but they are at least $80 each.

[grumpy72]

[grumpy72]

Lots to do. .my bike was referred to as junk. Its my junk. I love it.

[GrandpaDenny]

I am glad i finally reached a conclusion. I will make a new cable,use the old sleeve even though its in 2 pieces. I found a replacement cable for $10. If its the right length i dont have to make anything.wait till my friend gets the carbs done.hook the cables to them.push them back onto the head.shoehorn the airbox on.get the wretched springs back in place. Connect the choke cable, fuel and vacuum lines.slide the gastank back in.connect the filter. Hopefully it will start. It did before. I have never adjusted a cable before. I guess turn the adjuster till the slack is out, tighten the lock nut.see if the throttle opens right, snaps back when i let go of it. Then i have to replace both tires, get all the air out of the brakes, drill out the broken upper shock bolt and replace.remount the rear frame. I wanted to remove the upper fairing but I cant. Too many wires. But the fairing pieces with the pockets to help secure the fairing are either broken like the right side or completely missing like on the left side. I need both left and right but they are at least $80 each.

You don't want the throttle cable too tight. Specs are for 2-3mm "wiggle" at the throttle. The only cable that should be taut is the decel cable.

[grumpy72]

Thank you denny. I read the manual about the freeplay. I suspect too tight and the bike would rev up and not rev down anytime it was started, or the cable would break, and or the bike would idle at 5000 rpm. Thank you for the tip. For those who said my bike was junk, its like finding a 55 chevy in a field with no motor or transmission and 4 bald tires for $500. Its junk in the beginnig but oure gold when it is fixed.

[grumpy72]

Denny the cable i cut was the one that connected to the cruise control box. I dont know if on the carb side if it was connected to #2 or # 3.

[GrandpaDenny]

For those who said my bike was junk, its like finding a 55 chevy in a field with no motor or transmission and 4 bald tires for $500. Its junk in the beginnig but oure gold when it is fixed.

Gertrude was an $800 mess when I bought her. 2 1/2 years and 39000 miles later she's, well, not quite a gem as she's still got some issues, but I get tons of compliments on her (especially on the rare occasion that she's clean and shiny) and much more importantly, we have a BLAST together.

One day whilst out for a ride with the (now) friend I'd bought her from, I offered to let him ride her, so we traded bikes for a while. After ten minutes on his Virago 1100 I wanted my elephant back.

93000 miles on her and for the first time she's down, waiting for her new clutch kit to arrive in the mail. She wouldn't be down hard if I hadn't broken off two of the clutch cover screws taking the cover off to investigate. I'm planning to go down and fix that shortly. Might put the cover back on so as to be able to drive her with the sometimes slipping clutch until the kit arrives and until the brutal heat wave is over.

I've got the new spider/leaf springs, from Carl Leo, and could put them in now, and might, and that will probably help for now, but I'm not sure I want to take the clutch apart twice.

[grumpy72]

BRUTAL heat wave? Yesterday it was down to 109 here. 115 to 121 in surrounding towns. Cold front coming thisweekend.only 103. I can not reach Carl Leo. Leaf springs? There are no leafs on the bike. What are you talking about? I would like to put progessives and goldvalve emulators. I dont know if that is possible.

[GrandpaDenny]

They are springs in the clutch assembly, called spider springs or leaf springs. Did you email voyagerparts@bellsouth.net?

[grumpy72]

Yes thats the email i used. I got no answer. I guess i will try again

[GrandpaDenny]

Don't expect an immediate answer. Sometimes it takes him some days, maybe a week or two, before he answers. Make sure you say you're with the AVA as well.

[GrandpaDenny]

His phone number is in the classifieds. Click on the ad for voyager parts.

[grumpy72]

i appreciate it

[grumpy72]

My carbs are done. I got my replacement throttle cables yesterday. The right upper shock bolt that was broken was unobtainable. A 50 year master bike mechanic machined one and had it welded in place in less than 2 hours. Tomorrow reassembly begins. My junk bike as someone described it might be resurrected soon.