Installation Instructions for Throttle Line Oil Return Wire and Accelerator Cables for KLX250 (1992-2007) and KLX300 (1997-2007)

Tools Required:

1. Screwdrivers:

   • Flathead screwdriver
   • Phillips screwdriver

2. Wrench Set:

   • Adjustable wrench
   • Socket set (specifically 10mm and 12mm)

3. Pliers:

   • Needle-nose pliers
   • Regular pliers

4. Cable Cutters:

   • For trimming any excess cable if necessary.

5. Measuring Tape:

   • To measure cable lengths if adjustments are needed.

6. Lubricant:

   • Silicone spray or motorcycle cable lube for smoother operation post-installation.

7. Safety Gear:

   • Gloves and safety glasses to protect yourself during the installation process.

Installation Steps:

1. Preparation:

   • Ensure the motorcycle is parked on a stable surface.
   • Disconnect the battery to prevent any electrical shorts.

2. Remove Old Cables:

   • Use the appropriate screwdriver or wrench to remove the old throttle line oil return wire and accelerator cables.
   • Carefully note the routing of the old cables for reference during installation.

3. Install New Cables:

   • Position the new throttle line oil return wire and accelerator cables in line with the original routing.
   • Attach the throttle cable to the throttle body and secure it using the provided fittings.

4. Adjust Cable Position:

   • Utilize the flexibility of the new cables to adjust their position according to your riding habits.
   • Ensure there is enough slack for smooth operation without excessive tension.

5. Test the Mechanism:

   • Manually operate the throttle to ensure it returns smoothly and that there are no binding points.

6. Final Adjustments:

   • Use measuring tape to ensure cable lengths are appropriate. Trim as necessary with cable cutters.
   • Apply lubricant to the cables to enhance performance.

7. Reconnect Battery:

   • Once everything is in place, reconnect the motorcycle battery.
   • Double-check that all connections are secure.

8. Conduct a Test Ride:

   • Start the engine and conduct a short test ride to ensure everything functions properly.
   • Check throttle response and make any final adjustments if needed.

By following these steps and using the required tools, you can successfully install the throttle line oil return wire and accelerator cables, enhancing the performance and responsiveness of your KLX250 or KLX300. Enjoy your ride!