Information to assist in the adjustment/repositioning of the throttle assembly on the handlebars

KAOKO does from time-to-time encounter OEM variance, or inconsistencies, and which affect the successful and proper fitment of KAOKO products.

Inconsistency is seldom, and can include:

1. Component final assembly (eg. Throttle Assembly) outside our recorded OEM tolerance range 2. Different OEM components fitted (eg. Hand Guards, Handlebars, Bar End Weights)

Note: When such inconsistency is encountered, an adjustment to the throttle assembly position may be necessary to suit our KAOKO™ Throttle Stabilizer.

The throttle assembly position on aftermarket bars, and some OEM bars, is adjustable. The assembly can be marginally re-positioned along with the handlebars by slightly loosening the throttle assembly clamp screws, and then sliding the throttle assembly along the handlebars (left or right). Once done, firmly tighten the clamp screws to OEM torque specifications. This adjustment is generally not necessary.

Technical Assistance Questions:

A. Friction Nut (with Thrust Washer) does not thrust against plastic throttle sleeve on final assembly? To solve this complication.

1. Reposition the throttle assembly slightly outwards along handlebars (or closer to the end of the handlebars)

2. The excessive gap (or play) between the Thrust Washer and plastic throttle sleeve (part of throttle assembly) is now reduced and thereby allowing the thrust washer to thrust against the plastic throttle sleeve on final assembly (engagement).

See notes below on “Throttle Assembly Adjustment/repositioning”

B. Friction Nut (with Thrust Washer) binds against plastic throttle sleeve on final assembly? To solve this complication.

1. Reposition the throttle assembly slightly inwards along handlebars (or further from the end of the handlebars)

2. The insufficient gap between the Thrust Washer and plastic throttle sleeve (part of throttle assembly) is now increased.

Effectively you have now created more space in between the KAOKO Throttle Stabilizer (thrust washer) & the throttle assembly. The same additional space now prohibits the binding of the KAOKO Throttle Stabilizer (thrust washer) against the Throttle Assembly (plastic throttle sleeve) on final assembly (engagement).

See notes below on “Throttle Assembly Adjustment/repositioning”

C. After repositioning my throttle assembly, and completing final assembly of the KAOKO™ Throttle Stabilizer; - how do I know I have achieved the correct fitment and functionality?

1. Enquire with KAOKO if you are concerned about whether you have achieved proper and safe fitment

2. Follow the detailed fitting guide/instructions provided with the specific KAOKO™ Throttle Stabilizer you have fitted

3. Ensure that the below measures are consistent with your final assembly and product operation/functionality

Operation: The friction nut has left hand thread. In readiness for engagement, it must be adjusted so that it makes contact with the throttle sleeve.

To Engage:

While rolling on the throttle, the friction nut can be gripped between the small finger and palm of hand. This action tightens the nut and provides sufficient friction to set throttle to the desired opening. (The friction is such that the rider may still open and close the throttle. It simply has a slight rotational stiffness.)

To Disengage:

While rolling off the throttle, grip friction nut between small finger and palm of hand. VERY IMPORTANT!! The Throttle should open and snap closed freely when correctly disengaged. Please refer to the product fitting instructions for full details on assembly and product functionality.

THROTTLE ASSEMBLY ADJUSTMENT / REPOSITIONING

To adjust the throttle assembly position, - one first needs to determine whether the throttle assembly is “pinned” to the handlebars?

To determine whether your throttle assembly can be repositioned along the handlebars; proceed to “loosen” (do not remove altogether) your throttle assembly clamp screws and try to slide the entire throttle assembly outwards (or inwards) along the handlebar tubes.

If the throttle assembly slides in or out along the handlebars then your throttle assembly is not pinned and so can be repositioned slightly along the handlebars.

Note: mirrors and handguards may need to be adjusted along the handlebars to allow the throttle assembly to be repositioned.

A locating pin will prohibit throttle assembly adjustment/repositioning along the handlebars, and so the throttle assembly can only be mounted in one position along the handlebars, determined by the locating pin.

If the throttle assembly cannot be repositioned; and you experience problem A (binding) or B (excessive gap) above; please notify KAOKO and we will assist investigate further and assist with a proposed solution for your fitment.