DIY / HANDLE PARTS

Installing an AMAL Throttle Housing: From Choosing a Cable to Adjusting Free Play

The AMAL throttle housing has a classic look. We explain how to choose the right cable, the installation steps, and the safety-critical points of tightening the nuts and adjusting free play.

What you'll learn in this article

How to choose the right throttle cable for your bike
Installation steps for the AMAL throttle housing
Adjusting cable free play and safety checks after installation

The slim, classic AMAL throttle housing is a part that dramatically changes the look of the handlebar.

However, the throttle is a critical part that directly controls engine output. Using the SR as an example, we carefully follow everything from choosing the cable to installation and free play adjustment. The installation method is almost the same on other models.

01 First, choose the dedicated cable

Fitting an AMAL throttle housing requires a separate dedicated throttle cable (Universal Throttle Cable). The compatible cable type varies by model and year, and you also need to choose the length. Use the table below as a guide.

車種別の対応タイプと、ワイヤー長ごとの純正比（mm） — Compatible types by model, and length compared with stock for each cable length (mm)

適合表に載っていない車種は、キャブレター側の寸法を測って確認 — For models not in the fitment table, measure the carburetor side to check

POINT

Cables in the same length as stock aren't available, so we recommend choosing one with a little extra length (e.g. SR stock approx. 950mm → Universal Cable 1000mm).

02 Installation steps

Attach the AMAL cable to the carburetor.
Set the cable in the bottom of the throttle housing and seat the cable end in the sleeve slid onto the handlebar.
Fit the top cover and tighten the screws and nuts.
Tighten carefully while checking that the sleeve moves without catching or feeling odd.
If all is well at the throttle, move on to the carburetor side. Tighten the cable nut while allowing for free play in the inner cable.

Notes

If you ride with the carburetor-side nut left untightened and it works loose, the nut can get caught in the carburetor's opening mechanism and stop the throttle from closing. Make absolutely sure you don't forget to tighten it.

03 Adjusting the inner cable free play

After installation, adjust the inner cable free play. Depending on the amount of play, you'll see symptoms like these.

Too much play: the carburetor doesn't open when you twist the throttle
Too little play: the carburetor stays open all the time

Adjust by loosening (extending) the adjuster in the middle of the cable.

Notes

Always tighten the nut after adjusting with the adjuster.

04 Always finish with a safety check

Re-tighten everything once more and confirm nothing is loose. Then start the engine and slowly turn the handlebar left and right.

With too little play, the idle will rise just from turning the handlebar, which is very dangerous. If the idle changes, adjust the free play again.

Tighten every nut securely (a forgotten nut could lead to a serious accident)
Always check after adjusting the free play

POINT

If you have any doubts about the work, don't push it; ask your local shop to do it.

What we used

AMAL throttle housing
AMAL cable (Universal Throttle Cable)
Flat-head screwdriver
8mm wrench x2
10mm wrench x2

Products featured in this article

Throttle housings AMAL cables