Is there any play in your throttle at all? If not, I'd say someone tightened the cables too much. Look down the cables until you find the adjusters, and back them off until it stops binding. It's also possible they just need to be lubed, that is part of the regular maintenance and on that bike if it hasn't been done in all these years it would be getting pretty sticky by now. There could also be some crap in the housing, but that'd be the last thing I'd check.

There isn't a known weak link in the fuel gauge loop, but if you have a multi meter you can pull the cluster and check the gauge.

 

when I work the grip and look at the carb end of the cables, I dont see any play, I'll have to look for the adjusters... (I persume I need to take off some body plastics to get to those). judging by the guy who owned this bike before my buddy, I would be surprised if it had been lubed at all, I am familiar with the procedure on bicycles but have not done a ton with my ZX9 yet... a bit different than my cars to work on

 

No, play in the grip itself. You should be able to giggle it just a whisker before the cables move, I believe spec is 2-3mm IIRC.

 

yeah - there is no play in this

 

The first thing I would do is check the barend and make sure that it isn't too tight. Take the barend off and see how the throttle works. If it works fine without the barend then take care in re-installing it and make sure you don't push it in too far and tighten it too tight. Then I would start rooting around in the cables and throttle housing.

Don't know jack about the gauges. Could be a loose wire or cable...could be the gauges are toast. Don't know. Sorry.

 

I took off the bar end and it got a little easier, but not by much at all. I would guess its a binding cable, but I just don't know.

I may have to bring the bike in some time for an estimate and diagnostic on the fuel gauge.

 

Don't get overwhelmed by the throttle problem. Throttle cable systems are actually pretty simple. Trace back the cables and check springs, connection points, anything that rotates, etc. Then run some good cleaner and lube through the cables. If they're just kinda dirty and binding, that could solve your problem. Maybe they're toast and need to be replaced, but that isn't all that bad to do at all. Good luck.

 

Thanks much!

how do I remove the cables from the bike to clean them?

the spring looks to be in good shape on the carbs, who knows, with 24,000 miles the cables may need to be replaced anyway but I'd rather take them out and lube em' up if possible first

 

The easiest way I have found is to get a cable lubing tool. The directions that come with it will tell you exactly how but, all you've got to do is take the cable off at the throttle case and attach the tool. Then spray in the cleaner/lube until it you see it coming out of the lower end of the cable. If you use something to clean it first, like WD40 or something, make sure that you give it time for the cleaner to evaporate or blow out the excess or whatever. Just make sure you get most of it out before you spray in the lube.

 

ah, that makes more sense -- I'll try pulling the cable housing off of the grip assy. spraying in a cleaner (WD40) then once thats evaporated, spray in a lubricant.

hopefully that will solve my issue

Thanks for all the pointers so far!

 

just went out there, do I have to open up the grip assy to get at the cables?

it doesnt look like it would be very easy to get back together after that.

I just bought some aresol Silicone lubricant to spray the cables with but I am just confirming that I have to open the grip housing (2 Phillips screws)

 

Yup. It's not that bad. To make it easier, since you're at it and will have to adjust them later anyway, go ahead a loosen the cables up so they are easier to get back into the housing when you put it back together.

 

haha, alrighty -- I hope all goes swimmingly then

 

aaaalrighty. well. that silicone lubricant.... made it worse....?

any ideas, haha

 

The only thing I can think of is that the cables were so gunked up and full of dirt and other junk, that cleaning and lubing them just dislodged it all and bound it up somewhere.

I'll tell you what though, I think you just found out that the cables are your problem. If I were you, I'd just go ahead and order some new ones and get it over with. Odds are, those are the original cables...it may be time.

 

I'll just take it in -- couldn't hurt to have it looked at anyway.

 

check the routing on the cables off the housing at the clipon, mine had the wires routed through the front of the brake line, it was keeping the cables kinda kinked forward, now the cables are kinda snaky looking instead of a smooth bend and it holds the throttle similar to what you described

 

interesting -- I'll check