How to install a throttle cable model 3120xp

To remove a fuel injector or injectors you must remove the fuel supply rail that sits over them. Here is how you do that for both engine options, Turbo and non Turbo..

Removal & Installation

Except Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release fuel system pressure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Remove the engine cover or throttle control shield if equipped.
   NOTE Wrap shop towels around hose to catch any gasoline spillage.
5. Disconnect fuel supply tube from rail.
6. Remove the Intake Manifold, refer to the Engine section.
7. Disconnect electrical connectors from fuel injectors.
8. Remove bolts holding fuel rail.
9. Remove the fuel rail and injectors.
10. Remove the injectors from the fuel rail.

To install:

1. Install injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
4. Attach electrical connectors to fuel injectors.
5. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section
6. Install Intake Manifold, refer to the Engine section.
7. Install the engine cover or throttle control shield if equipped.
8. Install the negative battery cable.
9. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 20-30 inch lbs. (2-4 Nm).

Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release the fuel system pressure.
2. Disconnect the negative battery cable.
3. Disconnect the throttle body inlet hose and remove from throttle body.
4. Disconnect the purge hose from the throttle body.
5. Unlock and disconnect the electrical connection at the throttle body.
6. Remove the throttle control shield .
7. Remove the throttle and speed control cables from the throttle body.
8. Remove the cables from the throttle body bracket.
9. Unlock and disconnect the MAP sensor electrical connector.
10. Remove the vacuum lines from the rear of the intake manifold.
11. Remove the 5 bolts from the front of the intake manifold.
12. Remove the 2 bolts from the rear of the intake manifold.
13. Remove the intake manifold. Cover the lower intake manifold openings.
14. Drain the Coolant system.
15. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
16. Remove the 2 small hoses from the thermostat housing.
17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
18. Disconnect the fuel line from the fuel rail.
19. Unlock and disconnect the electrical connectors from the fuel injectors.
20. Remove the wiring harness from the fuel rail.
21. Remove the 2 bolts from the fuel rail.
22. Remove the fuel rail and injectors from the intake manifold.

To install:

1. Install the fuel injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
4. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
5. Install the wiring harness to the fuel rail.
6. Connect and lock the electrical connectors to the fuel injectors.
7. Connect the fuel line to the fuel rail.
8. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 110 inch lbs. (12.5 Nm).
9. Move the upper radiator house clamp back into place.
10. Install the 2 small hoses to the thermostat housing.
11. Fill the Coolant system.
12. Install the intake manifold.
13. Install the 2 bolts to the rear of the intake manifold tighten to 250 inch lbs. (28 Nm).
14. Install the 5 bolts to the front of the intake manifold and tighten to 250 inch lbs. (28 Nm).
15. Install the vacuum lines to the rear of the intake manifold.
16. Connect and lock the MAP sensor electrical connector.
17. Install the cables to the throttle body bracket.
18. Install the throttle and speed control cables to the throttle body.
19. Install the throttle control shield.
20. Connect and lock the electrical connections at the throttle body.
21. Connect the purge hose to the throttle body.
22. Connect the throttle body inlet hose to the throttle body and tighten clamps to 20-30 inch lbs. (2-4 Nm).
23. Connect the negative battery cable.
24. Use the DRB® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

Removal & Installation

Except Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release fuel system pressure.
2. Remove the air cleaner lid, disconnect the inlet air temperature sensor and makeup air hose.
3. Remove the negative battery cable.
4. Remove the engine cover or throttle control shield if equipped.
   NOTE Wrap shop towels around hose to catch any gasoline spillage.
5. Disconnect fuel supply tube from rail.
6. Remove the Intake Manifold, refer to the Engine section.
7. Disconnect electrical connectors from fuel injectors.
8. Remove bolts holding fuel rail.
9. Remove the fuel rail and injectors.
10. Remove the injectors from the fuel rail.

To install:

1. Install injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
4. Attach electrical connectors to fuel injectors.
5. Connect fuel supply tube to fuel rail. Refer to Quick Connect Fittings in the Fuel Delivery section
6. Install Intake Manifold, refer to the Engine section.
7. Install the engine cover or throttle control shield if equipped.
8. Install the negative battery cable.
9. Install the air cleaner lid, connect the inlet air temperature sensor and makeup air hose. Tighten air inlet tube clamps to 20-30 inch lbs. (2-4 Nm).

Turbocharged Models

WARNING Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or *****.

1. Release the fuel system pressure.
2. Disconnect the negative battery cable.
3. Disconnect the throttle body inlet hose and remove from throttle body.
4. Disconnect the purge hose from the throttle body.
5. Unlock and disconnect the electrical connection at the throttle body.
6. Remove the throttle control shield .
7. Remove the throttle and speed control cables from the throttle body.
8. Remove the cables from the throttle body bracket.
9. Unlock and disconnect the MAP sensor electrical connector.
10. Remove the vacuum lines from the rear of the intake manifold.
11. Remove the 5 bolts from the front of the intake manifold.
12. Remove the 2 bolts from the rear of the intake manifold.
13. Remove the intake manifold. Cover the lower intake manifold openings.
14. Drain the Coolant system.
15. Move the upper radiator hose clamp, so that the hose can be rotated up and out of the way.
16. Remove the 2 small hoses from the thermostat housing.
17. Remove the 2 bolts from the thermostat housing and rotate the assembly up and out of the way.
    NOTE Wrap shop towels around hose to catch any gasoline spillage.
18. Disconnect the fuel line from the fuel rail.
19. Unlock and disconnect the electrical connectors from the fuel injectors.
20. Remove the wiring harness from the fuel rail.
21. Remove the 2 bolts from the fuel rail.
22. Remove the fuel rail and injectors from the intake manifold.

To install:

1. Install the fuel injectors to the fuel rail.
2. Apply a light coating of clean engine oil to the O-ring on the nozzle end of each injector.
3. Insert fuel injector nozzles into openings in intake manifold. Seat the injectors in place.
4. Install the 2 bolts to the fuel rail. Tighten fuel rail bolts to 170-230 inch lbs. (19.5-25.5 Nm).
5. Install the wiring harness to the fuel rail.
6. Connect and lock the electrical connectors to the fuel injectors.
7. Connect the fuel line to the fuel rail.
8. Rotate the assembly back into place and install the 2 bolts to the thermostat housing tighten to 110 inch lbs. (12.5 Nm).
9. Move the upper radiator house clamp back into place.
10. Install the 2 small hoses to the thermostat housing.
11. Fill the Coolant system.
12. Install the intake manifold.
13. Install the 2 bolts to the rear of the intake manifold tighten to 250 inch lbs. (28 Nm).
14. Install the 5 bolts to the front of the intake manifold and tighten to 250 inch lbs. (28 Nm).
15. Install the vacuum lines to the rear of the intake manifold.
16. Connect and lock the MAP sensor electrical connector.
17. Install the cables to the throttle body bracket.
18. Install the throttle and speed control cables to the throttle body.
19. Install the throttle control shield.
20. Connect and lock the electrical connections at the throttle body.
21. Connect the purge hose to the throttle body.
22. Connect the throttle body inlet hose to the throttle body and tighten clamps to 20-30 inch lbs. (2-4 Nm).
23. Connect the negative battery cable.
24. Use the DRB® scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.

You have not listed your model.
Generally, remove two or three screws holding the right hand control module together. Remove old cable, install new cable in housing, and cable end in throttle tube. Reassemble.

REMOVAL
Loosen the cable adjuster jam nuts, screw the throttle cable adjuster until it is as short as possible, remove the two screws that hold the handlebar housing together to separate the upper and lower housings, unhook the ferrules and cables from the throttle grip and lower housing, remove the air cleaner assembly and disconnect the throttle cables from the carburetor, pull the cable from the housing by placing a drop of oil on the retaining ring that holds the cable in the housing, then firmly pull the bent tubing portion of the cable out of the housing using a rocking motion. The cables can be removed from the carburetor by pulling the outer housing away from plate above the throttle wheel and then with slack in the inner cable twisting the inner cable to allow the swaged end to release from the slot in the throttle wheel and then pull the inner cable out through the mounting plate hole.

If you will reuse the cable wash all components in non-flammable cleaning solvent, carefully blow all parts dry with low pressure compressed air, replace the control cables if frayed, kinked or bent, put one or two drops of oil into the housing of each control cable.

INSTALLATION
Apply a light coating of graphite to the handlebar and to the inside surface of the housings, attach the control cable assemblies to the lower housing, push the silver insert of the throttle cable housing into the hole in front of the tension adjuster screw, push the gold insert of the idle cable housing into the hole at the rear of the tension adjuster screw, install the adjusting screw, spring and friction pad in the lower housing if they were removed, position the throttle grip on the handlebar, place the lower housing on/over the throttle grip, position the ferrules and retaining rings over the cable balls and seat them in the throttle notches, fasten the upper housing to the lower housing using two screws tightened to 35-45 in-lbs (4.0-5.1 Nm), CHECK the throttle cable routing, on FXD, FXDL and FXDX models, the throttle cables are routed between the headlamp bracket and the front fork upper bracket and then under right side of tank to carburetor. On FXDXT models the throttle cables are routed through a wire form that is mounted on the upper fork bracket. On FXDWG models, the throttle cables are routed behind the front fork upper bracket, then under the right side of the fuel tank to the carburetor, install the throttle cables on the carburetor and adjust them at the handlebars and re-install the air cleaner. The throttle cables must be clear of steering stops and not be so tight that the idle speed will be changed when turned from steering stop to steering stop.

Throttle Cable Adjustment
To adjust the throttle cables turn the cable adjusters and jamnuts as short as they will go so that both cables will have zero adjustment at the start of the adjustment procedure. THEN with the front wheel pointing straight ahead turn the throttle grip wide open and hold it there, turn the throttle cable adjuster to lengthen the sleeve until the throttle cam just touches the cam stop. THEN tighten the adjuster jamnut and release the throttle. THEN turn the front wheel full right and turn the idle cable adjuster to lengthen the sleeve until the cable housing just touches the spring in the cable support sleeve. THEN recheck the adjustment by working the throttle grip to be sure the cable returns to idle position when released. If the cable does not return to idle, turn idle adjuster to shorten the sleeve until the correct adjustment is reached and then tighten the jamnut. The throttle control must operate freely without binding.

...ummm, there isn't a throttle cable on that model, do you mean the engine shut-off cable?

What year model. Take tank off. Take cover off throttle on handle bars. Release tension on throttle cable by loosening cable adjusters. Release cable from carburetor. Release cable from throttle housing on handle bar. Reverse instruction to install new cables ...2 cables.

This job os not to be taked on lightly, remove the hand guard by taking away the securing screw and pivots, be aware if you remove the roll pin without locking the spring and catch the locking lever can fly out under spring tention, i lock the top of the spring and catch, and the lower end of the spring in a vice ( this means the vice jaw is where the sprocket would sit, so be carful not to damage the cover ) then take the roll pin out, the top catch screws onto a thread on the band, be sure to count how many turns the catch is on the thread and re fit the same on the new band, it does not just bottom out

Removal & Installation

1. Disconnect the negative battery cable.
   
2. Disconnect the Intake Air Temperature (IAT) sensor connector.
   
3. Disconnect the breather hose from the valve cover.
   
4. Remove the air intake tube.
   
5. Disconnect the throttle cables by opening the throttle and moving the cable through the release slot.
   
6. Disconnect the vacuum hoses from the throttle body.
   
7. Disconnect the Throttle Position (TP) sensor and the idle air control valve connectors.
   
8. Disconnect the coolant hoses from the throttle body.
   
9. Remove the throttle body and discard the gasket.
   
10. Remove the TP sensor.
    
11. Remove the Idle Air Control (IAC) valve.
    
12. Remove the throttle body retaining nuts.
    
13. Remove the throttle body.
    

To install:

1. Install the throttle body.
   
2. Connect the TP sensor connector and the IAC valve connector.
   
3. Connect the coolant hoses to the throttle body.
   
4. Connect the vacuum hoses to the throttle body.
   
5. Connect the throttle cable.
   
6. Install the air intake tube.
   
7. Connect the breather hose to the valve cover.
   
8. Connect the IAT sensor connector.
   
9. Connect the negative battery cable.
   
10. Fill the cooling system
    
11. 
12. i hope this helps tps is attatched to hrottle body on other side than throttle cable
    
13. plz dont forget to vote rep[ly if you need more help
    

Idle Air Control Valve Pintle may be bad If you disconnect the IAC and the problem ceases it can point to this being the problem.: Removal & Installation 3.5L Engine To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove the fuel injector sight shield.
3. Drain the cooling system.
4. Remove or disconnect the following:
   • The air cleaner intake duct. Figure of IAC and TPS electrical connectors disconnected.
     
     
   • The idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Figure of cruise control and throttle control cables removed from throttle lever.
     
     
   • The cruise control cable and throttle control cable from the throttle body lever.
   • The fuel pressure regulator vacuum hose, positive crankcase ventilation (PCV) hose and the throttle body vacuum port hose.
   • The throttle body coolant hoses.
   • The throttle control cable bracket, leaving the throttle and cruise cables connected.
   • The upper nut holding the throttle body to the intake manifold.
   • The throttle body assembly.
5. Clean the gasket mating surfaces.

To Install:

1. Install a new gasket and new studs if necessary.
2. Install or connect the following:
   • The throttle body assembly.
   • Start the top nut by hand.
   • The throttle body coolant hoses.
   • Position the throttle control cable bracket and hand start the retaining nuts and bolt.
   • Torque the three throttle body retaining nuts to 89 in.lbs. (10 Nm). And the bracket retaining bolt to 115 in.lbs. (13 Nm).
   • The throttle body vacuum port hose, PCV valve hose and the fuel pressure regulator hose.
   • The throttle control and cruise control cables to the throttle body lever.
   • The IAC valve and TP sensor electrical connectors.
   • The air intake duct.
3. Refill the cooling system.
4. Install the fuel injector sight shield.

4.0L Engine To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Relieve the fuel system pressure.
3. Remove or disconnect the following:
   • Negative battery cable.
   • The Mass Air Flow (MAF) sensor electrical connector.
   • The air cleaner intake duct.
   • The PCV valve fresh air tube. Figure of cruise control cable removed from throttle cable bracket.
     
     
   • The cruise control cable and throttle control cable from the bracket.
   • The cruise control cable and throttle control cable from throttle body lever. Figure of IAC valve and TPS connectors removed.
     
     
   • The idle air control (IAC) valve and throttle position (TP) sensor electrical connectors. Figure of fuel lines removed from retainer on throttle cable bracket.
     
     
   • The fuel feed and return lines from the retainer on the throttle control cable bracket.
   • The transaxle shift cable clip from the throttle control cable bracket. Figure of throttle body removed from water crossover.
     
     
   • The throttle body from the water crossover.

To Install:
NOTE: The Mass Air Flow (MAF) sensor inlet and the outlet of the air cleaner assembly must line up when installed. Misalignment may cause MIL illumination or driveability concerns.

1. Install or connect the following.
   • The throttle body to the water crossover. Torque the bolts to 106 in.lbs. (12 Nm).
   • The IAC valve and TP sensor electrical connectors.
   • The throttle and cruise control cables to the throttle body lever.
   • The throttle and cruise control cables to the throttle control cable bracket. The transaxle shift cable clip to the throttle control cable bracket.
   • The fuel feed and return line retainer to the throttle control cable bracket.
   • The MAF sensor electrical connector.
   • The air cleaner intake duct clamp. Torque the clamp to 27 in.lbs. (3Nm).
   • The PCV valve fresh air tube.
   • The fuel injector sight shield. Torque the nuts to 20 in.lbs. (2.3 Nm).
2. Install the negative battery cable.
3. Pressurize the fuel system and verify no leaks.

Put both cables side by side. Are they the same length? Probably not. Go back to the dealer with both cables and ask what's going on with them. It could be that the prior owner installed a non-stock throttle then had the bike shop make a cable to fit, or the longer cable came with the throttle kit.

Your options are to get a new cable made to match the old cable or get a stock Harley throttle. If the throttle already IS a stock Harley part, then I would think the listing of what models the part would fit is incorrect. Have the guy at the parts counter try to match up cables.

Please rate this solution. Thanks!