Full Throttle Polaris 007-1031 User Manual

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2) Look on the back side of the throttle block on the right side, on the bottom there is an opening to a hollow cylinder, starting from
the bottom, screw the adaptor plate bolt into the open hole in the throttle block. The barrel bolt should be on top and pointing to-
wards the other side of the handle bars. Be sure to screw the adaptor bolt all the way into the cylinder on the throttle block.

Part 3: Routing of Cable Shroud From Left Throttle to Right-Side Cable Attachment

OBJECTIVE: The goal in this section is to connect the right side throttle with the Goldfinger on the left side using the

cable and cable housing. (See Picture C)

1) In order to protect your cable we recommend
that you route the cable from the left side to the
right side by going underneath the handlebar
padding, on models so equipped. To do this
you will first need to remove the center handle-
bar padding. Most snowmobile models have
either zippers or a velcro closure system which
you will first need to open before removing the
foam padding.

2) Take the stainless steel cable and insert the end without the head into the black cable housing, starting at the end with the
stainless steel cap and push all the way through until it comes out the other end.

3)Push the “hammerhead” cable end into the slot on the back of the left throttle lever and thread through the end of the lever

as shown in picture E.

4) Route the cable across the handlebars and through the hole in the rounded end of the bullet bolt (you may need to loosen
the small bolt slightly to allow the cable to pass through the hole). It is very important that the cable follow as straight a line
as possible to the right side in order to reduce kinks or binding, which may cause friction. (TIP: It typically works best to run
the cable UNDERNEATH the brake line and wiring harness on the LEFT SIDE of the handlebars, but OVER
the wires and Original throttle cables on the RIGHT SIDE of the handlebars.)

5) With the left throttle in the fully-closed position, check to make sure the ferrell capped end of the cable housing is pushed
all the way into the left-throttle assembly. Next, on the right side, measure 1 ¼” to the LEFT of the rounded end of the bullet
bolt and make a mark on the black cable housing.

6) Next, remove the cable from the bullet bolt and housing, slide the stainless cable far enough into the housing so you don’t
cut through the cable itself. Use a sharp pair of diagonal cutters (dikes) to cut the excess cable housing. After trimming
cable shroud, inspect end for any burrs or obstructions which might need further trimming.

7) Next take the ferrel end and put it on the end of the cable housing and with a pair of pliers lightly crimp the sides a couple
of times to secure it to the end of the housing.

8) Now, push the stainless cable back through the cable housing, making sure the cable slides smoothly in and out of the
housing.

9) Next, run the bare end of the cable through the large end of the rubber accordion boot, and pull the boot up until it slides
onto the end of the cable housing.

10) Insert stainless cable through hole in the rounded end of barrel bolt. For now, leave excess cable hanging out of the end
of the bullet bolt, and secure the newly routed cable shroud with a zip tie onto the left and right side of the handlebars. Pull
the zip ties snug, but not so tight as to kink the cable, then cut off the excess length from each zip tie.

11) Replace the handlebar padding and cover.

Part 4: Left Throttle Adjustment

THE FOLLOWING IS THE MOST CRITICAL PART OF THE INSTALLATION PROCESS!
1)

Turn the left throttle perch adjuster ring all the way in (clockwise).

With the right throttle in the FULLY CLOSED position and while holding the throttle plate from moving, pull the bare ca-
ble end tightly to the right to eliminate slack in the cable (pliers or vice grips help to grip the cable).

Using the Large allen wrench, tighten the short allen screw into the barrel bolt to secure the cable. DO NOT TIGHTEN
COMPLETELY until you are satisfied with the adjustment of the cable (this will flatten the cable inside the barrel bolt,
making it more difficult to adjust).

Slowly engage the left throttle (with the engine off, of course--we had to put that in for obvious legal reasons) while
watching the movement of the right-side adapter plate. If adjusted properly, the right throttle should open fully, and then
CLOSE COMPLETELY when left throttle is released. If it does not do this, continue adjusting position of cable inside
barrel bolt until throttle opens and closes fully. When satisfied with adjustment, tighten allen screw into barrel bolt.
(NOTE: There should be one washer between the allen bolt head and the top side of the adapter plate, and another
washer between the plate and the barrel bolt. When the allen bolt is tightened completely into the barrel bolt it will se-
cure the cable, but there should still be a tiny bit of clearance so the barrel bolt can rotate freely without binding.) Use
your best judgment so you don’t strip threads in the barrel bolt (we’ve never done it yet, but we’re sure someone out
there might be stronger than us….)