.

The throttle cables are now installed and fully synchronized according to the service manual, along with the oil pump cable.

This was my first time doing this job. The synchronization went smoothly, but the installation itself was quite a challenge.

The real challenge was attaching the cable to the piston — as shown in the photo. The J model uses a smaller piston, while my bike is fitted with K model carburetors, which have longer pistons.

That extra length made it very difficult to get the cable all the way down and properly secured. In the end, I used a piece of dental floss to guide and pull the cable into position. A simple trick, but it worked.

Synchronizing:

I adjusted the alignment according to the service manual. Make sure that all the punch marks line up at the same level when you slightly twist the throttle.

Oil pump wire:

The throttle cable has four inner wires — three for the carburetors and one for the oil pump. The longest one is for the oil pump.

I followed the procedure according to the service manual, but take a close look at the photo below. There are two additional small punch marks, in addition to the one described in the manual.

The manual states that the red punch mark (No. 3 in the photo above) should be aligned with the green mark (No. 4) when the punch marks on the pistons are at the top position.

This is one way to do it. However, you can also align the smaller punch mark (No. 2) with No. 4 — but in that case, the punch marks on the pistons should be positioned in the middle.

I tried to follow the instructions in the manual, and afterwards, when lowering the piston mark to the center position, I noticed that punch mark No. 2 was aligned with No. 4.

In other words, both adjustment methods will work fine.

Olil Pump Wire Retainig Clip:

The plastic retaining clip was missing. Originally, the clip was made of metal, but all aftermarket replacements are produced in plastic.

I had no idea where to buy one, so I used my 3D resin printer and made a batch of them in tough plastic resin.

With resin printing, the height of the part is what determines the print time. A part like this takes about one hour to print — whether you make one or a hundred.

I printed 25 in one go. I’ll be giving them away at the Classic Suzuki Rally in Norway to anyone who dares to use one 🙂

All done: