Since we are on the subject of throttles, I want to revisit this problem. I decided to do a comparison between three different cables as well as the different throttle assemblies. I will be comparing the cable I got from Packard (sorry don't know what brand), the OEM kawasaki kx500 cable, and the Motion Pro Vortex Lectron cable. The two throttle assemblies I will be comparing are the OEM (2000 KX500) throttle assembly as well as the Packard Magura Duo 314 throttle assembly. I mainly want to do this comparison as a way to possibly help others that may be considering a Lectron carburetor. No one has really discussed the issue much, so I hope to help others out. Here are my thoughts and findings.
This first picture shows all three cables side-by-side. I was not able to get a picture of the cables showing the throttle side end. You'll just have to take my word when I say that I paired them next to each other evenly. The Packard cable is pictured at the very top, the OEM cable is in the center, and the last one is the motion pro vortex Lectron cable.
Looking at this picture, you'll see that both the aftermarket cables are longer than the OEM Cable. The Packard cable is a whopping 5 3/4" longer than the oem cable, that's quite the difference - I couldn't find a good routing solution for it. I also noted that it doesn't have a threaded end that goes into the carburetor top, nor does it have a threaded end that goes into the throttle housing. The non-threaded ends make me leery of using this cable because it would be fairly easy for each end to pop out. Of course, you could always fix this by wire-tying both ends. Next up, you'll notice that the Motion Pro cable is approximately 2 1/4" longer than the OEM cable, not enough to cause routing problems. This cable has threaded ends on both sides of the cable (into the carburetor, as well as into the throttle housing). I would have no problem using this cable. Lastly, we have the OEM throttle cable. This cable is 2 1/4" shorter than the motion pro cable, and 5 3/4" shorter than the Packard cable! I had no issues with routing this cable - sure, it could've been an inch or two longer - that would've been nice. I'll leave you to come up with your own conclusion on this one.
As our last comparison, I want to show the difference between the OEM throttle (2000 KX500) and Packard's Magura Duo 314. Here is a picture of the two assemblies side-by-side. The one on the right is the Magura, the one on the left with the white throttle tube is the OEM throttle assembly (it does have a motion pro throttle tube).
Take notice of how the two assemblies are shaped differently. The magura is completely round, while the oem throttle has a more square cutout on the back. I could not get the magura to work with my build. No matter which way I positioned the assembly, it just kept interfering with the front brake lever. This was due to the round shape on the back of the throttle. The oem throttle fits great, I have no issues with it. As a final note, the Magura housing is plastic, while the OEM assembly is metal.
Let's a look inside each throttle. The throttle on the right is the OEM, the throttle on the left is the Magura.
Both assemblies are very different. I like the fact that the Magura has a throttle reel design (very similar to a kx250 throttle). The OEM kx500 throttle has more of a basic design. I would assume that the Magura throttle would be smoother feeling based on the reel design.
Here's a deeper look at where the cable comes in to the Magura throttle housing.
Take notice that there aren't any threads for where a cable can screw into the housing. This assembly was obviously made to not accept a threaded throttle cable. This is a concern because the only thing that holds the cable in is the brass/metal fitting (in the case of the Packard cable - which is the only cable that will fit). It simply creates a slip-fit. Yes, I know the end of the cable is held by the throttle tube. Still, you can quite easily pull the cable right out of the throttle housing. Remember the throttle problems with the 12-13 KTM 2 strokes? This is a real concern because something could catch the cable (ie. a stick or tree branch, etc) and pull the cable, causing a whisky throttle. This could be fixed by wire-tying the throttle cable sheathing to the housing piece where the cable joins. Then slip the weather seal over it, problem solved and you won't even see the wire tie.
Here's a deeper look at where the cable comes in to the OEM throttle housing.
I really like how the throttle housing is threaded where the cable comes in. Only thing I like better about the Magura is the throttle reel, possibly smoother throttle? With it being threaded, no chance of the cable snagging.
Let's look at the Magura's throttle cap/top piece.
You can see by the yellow arrows how the cutout on the top further prevents the cable from jumping out of the throttle reel. Very nice design.
Let's look at the OEM throttle cap/top piece.
You can see by the yellow arrows how the top piece has a scalloped stop for the throttle end. I think its safe to say that it's a very safe design, I don't think there's any chance of the cable coming out. Also a very nice design.
That's it for now, hopefully everyone else finds this as interesting as I did.
