Replacing stock Harley-Davidson Throttle Assembly with Biltwell Whiskey Throttle:
STEP 1: Organize your tools. Two Torx drivers are required: one for the brake lever clamp and a second smaller size for removing the throttle control pod. Other tools include a 4mm Allen wrench for the Whiskey throttle clamshell and one each 3/8-inch and 10mm open-end wrenches to fine-tune cables after assembly. Depending on the accessibility of the throttle cable(s) at the carb, you may need tools to remove the breather. Other materials shown include a strip of 200-grit sandpaper, some masking tape and light assembly lube.
STEP 2: Remove the Torx bolts and clamp from the front brake lever and loosen the Torx on the throttle pod. Carefully remove the master cylinder assembly from the locating tab inside the throttle control pod and move it out of the workspace.
STEP 3: Open the throttle control pod and slide the throttle grip off the handlebar end. Depending on the length of your control wires and/or the width of your handlebars, it may be necessary to remove the bars from the risers.
STEP 4: Remove the cable ends from the old throttle grip, being careful not to lose the brass barrels during this process. Remove both complete cables from their holes in the stock throttle pod. Depending on your bike%u2019s cable style and model year, the cables will either clip in (identified by the non-threaded ferrule on the cable housing) or screw in (older threaded barrel adjuster ferrule style).
STEP 5: Six threaded cable ferrules are included with your Whiskey throttle: two sizes for clip-in cables, and four internally threaded styles for cables with screw-in barrel adjusters. Before proceeding, you must select the correct combination of ferrules based on the design of your cable(s). The cables on our 2007 demo bike are clip-in style, as shown in this photo. NOTE: two sizes of ferrules for clip-in cables are supplied with your Whiskey Throttle: Large ID (for Pull/Accelerate cable) and small ID (for Push/Return cable). On custom aftermarket throttle installations, we prefer to eliminate the Push/Return cable and only run the Pull/Accelerate cable. For these instructions we used both cables to show the Whiskey throttle in proper retrofit configuration.
STEP 6: Fit the brass cable barrel end(s) in the alloy tube of your Whiskey throttle. Depending on their age, size or condition, it may be necessary to hone out the barrel holes on the throttle tube for a smooth fit. If this is the case, proceed to step 7. If the brass barrel ends slip into your Whiskey throttle tube easily, skip to step 10.
STEP 7: Make a honing tool by taping a strip of medium-grit sandpaper to the end of a small Allen wrench.
STEP 8: Twist the honing tool gently inside both barrel slots on your Whiskey throttle tube. Doing so will remove any microscopic burrs that have been left behind during the CNC manufacturing process.
STEP 9: Check your progress periodically by inserting the brass barrel into the hole on the throttle tube. When you are satisfied with the ease of barrel fitment, repeat step 8 for the Push/Return cable.
STEP 10: To make installing the Whiskey throttle tube easier, you may find it helpful to remove the cable ends from the cam-shaped throttle actuator on your carburetor or fuel injector. Depending on the length and routing of your cables, it may be necessary to remove the air cleaner to gain access to this part of your fuel system. Do this according to the manual for your model of air cleaner.
STEP 11: Slip the correct threaded cable ferrule you selected in step 5 onto the Pull/Accelerate cable.
STEP 12: Put a drop of Lock-Tite on the threaded cable ferrule and pass the cable%u2019s lead ball through the Pull/Accelerate hole on the Whiskey throttle clamshell. This is the hole closest to the stop pins visible on the flat side of the clamshell.
STEP 13: Gently tighten the threaded ferrule into the clamshell. If you are using the Push/Return cable, repeat steps 11, 12 and 13 for this cable.
STEP 14: Slip the lead ball of the Pull/Accelerate cable into the brass barrel and insert the ball/barrel assembly into the Pull/Accelerate hole on the throttle tube. If you are using the Push/Return cable, repeat this step for the other cable.
STEP 15: This photo shows the proper way to install both stock cables on your Whiskey throttle. As stated earlier, you may opt to eliminate the redundant Push/Return cable on your custom set-up.
STEP 16: Apply a thin coating of light assembly lubricant to the inside of the Whiskey throttle tube and slide the sub-assembly into the handlebar end.
STEP 17: Install the second half of the Whiskey throttle clamshell on the alloy throttle tube sub-assembly. Lightly grease the threads of the two 4mm Allen cap screws supplied with your Whiskey throttle and thread them gently into the clamshell. Keep the split seam of the clamshell assembly even by turning each screw 1-2 turns, then switching to the opposite screw. Do not tighten the Whiskey throttle assembly in place yet.
STEP 18: Pull the carb ends of both throttle cables tightly and reinstall them on the throttle actuator, making sure to install each one in their correct hole on the cam. The Pull/Accelerate cable on the throttle pulls against the spring tension of this cam and opens the butterfly; the other cable fastens into the remaining hole on the cam to close the butterfly when you twist the throttle grip clockwise. Do not re-install the breather assembly yet.
STEP 19: Check endplay on the Whiskey throttle tube by holding the alloy tube in your hand and gently wiggling it back and forth along the plane of the handlebars. There should be approximately 1/8-inch of endplay between the Whiskey throttle tube and the clamshell assembly. If the throttle assembly is mounted too far inward, the Whiskey throttle tube will bind against the clamshell and/or the end of the handlebar. Either condition will inhibit smooth throttle operation. When endplay is correct, gently tighten the clamshell. Do so by turning each Allen cap screw 1-2 turns, then moving to the opposite screw. Follow this pattern until the clamshell is tight on the bars. NOTE: very little bolt torque is required to secure the Whiskey throttle to the handlebars. DO NOT OVERTIGHTEN.
STEP 20: Check cable play at the throttle by turning the throttle back and forth approximately 1/16th of a revolution in its housing. When the Pull/Accelerate cable is tensioned correctly, butterfly actuation should be immediate. If the throttle tube moves more than 1/16th of a revolution before actuating the butterfly, take up cable slack by extending the threaded barrel adjusters on the cable. This increases the effective length of the cable housing to take up slack at the throttle. Use two open-end wrenches to secure cable adjustment once proper throttle action is achieved.
FINISHING UP: If you removed the air cleaner, re-install it at this time. Start (BUT DO NOT RIDE!) your motorcycle to check throttle function. If the bike idles high, check cable play adjustment as described in step 20. If throttle tube play has been adjusted too precisely, this can cause the bike to rev higher than appropriate at rest. Next, make sure your throttle doesn't stick under acceleration. If this occurs, check throttle tube endplay as described in step 19.