This modification will make it so you do not have to turn the throttle as much to get the throttle all the way open. This is so that you do not have to reposition your hand on the throttle to open it all the way. It is very useful to those who ride on the track.
A little warning about this modification.
This WILL make the throttle more sensitive. You will not have to open it as much to get the same amount of power as the stock throttle.
Things you need:
PVC pipe - 1 3/8 in
Dremel
Throttle off of your bike or a new one
Some type of glue (I used Loctite Super Glue)
Some sandpaper
This was done on a 2004 R6.
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Sorry for the blurry pics, they were taken with my camera phone.
The unmodified stock throttle should open this much to get WOT.
First, go to any hardware store that sells PVC pipe and have them cut you a small piece of 1 3/8in pipe.
Remove your throttle from your bike. When doing the rest of this modification, I found it easier to detach the brake lever and right side ram air cover so they don't get in the way.
Now put the PVC pipe up against the throttle and mark where you want to cut it.
Cut the piece of pipe where you marked it at and slide it on the throttle tube.
Cut it some more if you have to to make sure the piece of pipe seats properly around the tube.
Now take it off the throttle, and using the dremel, round off the edges of the piece pipe. It should end up looking something like this.
Use some glue and glue it onto the pipe. You can use some sand paper to smooth it out if you want to.
--Make sure that the PVC pipe is not wider then the part of the tube you are glueing it to. If it is then it will rub against the housing and prevent the throttle from snapping back.--
Take the throttle housing off the clip on and remove the throttle lines from the housing. You're going to have to grind down the metal throttle line tubes so that they don't rub against the PVC. You will also need to grind down some parts inside the throttle housing itself. I've circled the parts that I grinded down using a dremel. (sorry that it is a little blurry)
Now you will have to loosen the throttle cable as much as possible. Here is the page from the service manual that explains how to do it.
Once it is loosened, you can now put the throttle back in.
Once you have it in, play around with it making sure that it is not rubbing anywhere. Turn the handle bars all the way to the left and right. When the handles bars are all the way to either side, rotate the throttle and let it go. It should snap back to its closed position. If it doesn't, then you may have to grind down some more parts because something is rubbing somewhere.
This is how much your throttle should turn when you are complete with this project.
How to: Make a 1/5 turn throttle
Linear Mode
