Coleman Mini Bike Throttle Cable

Riding a mini bike can be an extremely fun and freeing experience. Zooming around neighborhoods, dirt trails, or your own backyard on one of these small motorcycles brings back that childlike feeling of adventure. However, like any machine, mini bikes require proper maintenance and occasional repairs to keep running smoothly. One of the most important components is the throttle cable, which connects the throttle grip to the engine’s carburetor or fuel injection system. When this cable becomes damaged or worn out, it can prevent you from properly controlling the speed and acceleration of your mini bike. Replacing this part may seem daunting, but is actually a straightforward process, even for beginners. In this article, we’ll walk through the steps for replacing the throttle cable on a Coleman mini bike model.

What is a Throttle Cable?

The throttle cable is the mechanical link between the twist-grip throttle on the mini bike’s handlebars and the throttle plate in the carburetor or fuel injection body. When you twist the right grip towards you, the throttle cable pulls open the throttle plate in the carburetor, allowing more air and fuel into the engine. This increases the engine’s rpm and makes the mini bike accelerate faster. When you let go of the grip, the throttle plate closes again, slowing down the engine.

Over time, the inner wire inside the throttle cable housing can become frayed from friction and vibration. Dirt and debris can also get into the housing, causing the cable to stick. In addition, the cable housing ends often crack from fatigue. Any of these issues can make the throttle sluggish or even completely inoperable. Replacing the cable restores smooth and responsive throttle control.

Buying a New Coleman Throttle Cable

Fortunately, most major mini bike manufacturers offer replacement throttle cables for their various models. For a Coleman mini bike, you’ll want to search for a cable made specifically for that brand and designed to fit your bike’s year and engine size.

Coleman cables can be found at powersports dealerships or ordered online through parts retailers like Amazon, eBay, or direct from the Coleman Powersports website. Expect to pay $10-20 for a new cable. You’ll also want some lightweight lubricant like WD-40 to apply after installation.

When buying, it’s a good idea to note your Coleman model name and number, usually found on a sticker under the seat or near the vin number plate. This ensures you get the right cable for your specific bike. Some key measurements like overall cable housing length and inner wire length may also be provided in the product description to confirm compatibility.

Removing the Old Throttle Cable

Replacing the throttle cable first requires removing the old worn out cable. This involves disconnecting it from both ends and pulling it out of the housing. Here are the basic steps:

1. Turn the fuel valve or petcock to the OFF position before starting. This prevents any fuel leaks.
2. Remove any necessary body panels or covers to access the throttle cable mounting points. This may require taking off the air filter housing, fuel tank shrouds, or side panels.
3. Locate the throttle cable adjustment nut and locking nut near the carburetor/fuel injection body. Loosen the adjustment nut several turns and slide it down the cable housing.
4. Now loosen and slide back the locking nut. This releases the cable end from the throttle control arm on the carburetor/injector.
5. Twist the throttle a few times to unwind the cable from the grip throttle wheel. Pay attention to how the cable is routed as you unravel it.
6. At the handlebar, slide back the grip housing and carefully pull the cable end out of the grip throttle wheel.
7. With both ends free, slide the cable out of the housing. Inspect the condition of the housing and keep it if still in good shape.

Installing the New Coleman Throttle Cable

Once you have the worn out cable removed, it’s time to install the new replacement cable:

1. Apply a little WD-40 or similar lightweight lube to the new cable’s inner wire. Don’t use grease which could attract grit.
2. Feed one end of the new cable into the housing, keeping it aligned without kinking.
3. Thread the cable through the same routing as the old one. Refer to any photos you took during removal if needed.
4. Pull the cable through and insert the nipple end into the hole in the throttle grip wheel. Center the grip housing over the handlebar and push it back into place.
5. At the other end, hook the cable nipple into the control arm on the carburetor/injector body.
6. Slide the locking nut over the end and tighten it down to hold the cable in place.
7. Thread the adjustment nut onto the threads and tighten it down until tension is felt in the cable. Then back it off 1/2 turn. This sets the proper slack.
8. Do a final check that the throttle snaps shut completely when released. Rev the throttle a few times to make sure it operates smoothly.
9. Reinstall any shrouds, covers or air filter housing removed earlier. Double check that the cable does not catch or bind with the reinstalled parts.
10. With the new cable installed, reconnect the fuel line, turn the fuel valve ON and start the engine. Test ride the mini bike and make sure the throttle responds properly before regular use.

Properly installing the new throttle cable takes a bit of patience, but ensures safe and reliable throttle operation. Following the step-by-step process reduces the chance of errors. Refer to your specific Coleman mini bike service manual if you have any questions during the process. And don’t be afraid to call the Coleman support line for tech assistance either. Once replaced, your mini bike’s throttle will be sharp and responsive for many miles of fun ahead.

Troubleshooting Coleman Throttle Cable Problems

A sticking, sluggish or disconnected throttle cable can manifest in several ways. Here are some common throttle cable issues and fixes:

• Throttle stays open when released – This dangerous issue is often caused by a stuck cable or severely frayed inner wire. Replacing the cable should resolve it. Check that the new cable can move freely in the housing without binding.
• Throttle has no resistance and does not open carburetor – If the throttle grip spins freely with no resistance, the inner cable is likely broken or detached. Reconnect or replace the cable.
• Throttle hesitates or feels rough when turning – Fraying or kinking of the inner wire can cause friction in the cable. Lubricating or replacing the cable will smooth out throttle function.
• Throttle adjustment has no effect – If turning the adjuster nuts does not add cable tension as expected, the inner wire may be broken or disconnected. Inspect the cable ends and replace if necessary.
• Throttle grip housing is cracked or damaged – The grip housing anchors the cable end to the handlebar. Replace it along with the cable for smooth operation.
• Carburetor throttle arm is worn or loose – The control arm pin where the cable attaches can wear out over time. This may call for replacing the carburetor or just the arm.
• Housing is kinked or cracked – Cable housings can become damaged from vibration or improper installation. Replace any worn out housing.

Catching throttle cable issues early allows a quick fix before they leave you stranded. Always inspect cables regularly and replace at the first sign of damage. Following proper installation procedures also prevents many problems down the road.

Adjusting the Coleman Throttle Cable

The throttle cable adjustment nuts fine tune the tension in the cable to give smooth throttle response. The ideal setting allows the carburetor throttle plate to fully close when the grip is released, without making the twist-grip feel stiff and hard to turn.

Here are some tips for getting the adjustment right:

• With the cable installed, turn the adjusters all the way in until snug.
• Then back the nuts off several turns to give some initial slack. Throttle should snap shut off idle.
• Turn throttle to wide open position and hold there.
• Slowly turn the adjuster nut clockwise until resistance is felt.
• Then back the nut off 1/2 turn. Check for free throttle movement.
• Make small additional adjustments in 1/4 turn increments to refine the feel and return spring action.
• Make sure adjustments are even on both ends of the cable.
• Always check idle speed after adjusting and tune as needed.
• Consider new cable housings or lubricating to improve sluggish response.

Proper cable adjustment removes slack without creating throttle stiffness. The goal is smooth operation over the full range of throttle input. Fine tuning the adjusters helps compensate for cable stretch over time. Refer to your owner’s manual for the ideal factory settings.

Coleman Mini Bike Throttle Cable FAQs

Here are answers to some frequently asked questions about Coleman mini bike throttle cables:

Q: Where can I find the cable routing diagram for my specific Coleman model?

A: The best reference is your bike’s factory service manual. Also check for a schematic under the seat or in the manual packet. Online parts diagrams from Coleman or aftermarket parts sellers can also provide routing detail.

Q: My new cable has multiple adjusting nuts. Where do they go?

A: Most cables have two adjuster nuts – one for the throttle wheel end and one for the carburetor end. Install them in the same original locations and adjust per instructions.

Q: What type of lubricant can I use on the throttle cable?

A: A lightweight oil like WD-40 works well to lube the inner cable. Do not use grease or heavy oils which can attract dirt. Apply lubricant sparingly.

Q: How can I tell when it’s time to replace my throttle cable?

A: Fraying, kinking, cracking, throttle sticking, loose cable ends, or grip damage mean replacement is due. Also replace as routine maintenance every 1-2 years.

Q: Will an aftermarket cable fit as well as an OEM part?

A: Generally yes, as long as it’s designed for your specific Coleman model. Stick with reputable brands that specify compatibility for best results.

Q: My new cable is binding in the housing. What should I check?

A: Binding is often due to misaligned housing or cable ends not seated fully. Disconnect the cable, lubricate it, and carefully reinstall per the routing diagram.

Q: Can I adjust my Coleman throttle cable without tools?

A: Yes, the nuts can be turned by hand once the locking nut is loosened. But a narrow wrench gives more precision and ensures proper tightness.

Proper throttle cable selection, installation, and adjustment keeps your Coleman mini bike running safely. Follow the steps outlined here and enjoy the thrill of operating your bike just like it came from the factory. Checking the cable regularly and replacing it when worn maximizes performance and riding enjoyment.