Introduction
Nothing ruins a trail ride faster than a throttle that refuses to snap back. Most riders run into this at some point: dirt, rain, and normal wear cause the throttle cable or housing to stick. Over time, these components can become worn, sticky, or damaged — making the bike difficult or even unsafe to operate.
This guide shows you how to replace the entire throttle assembly on a Coleman CT200U‑AB minibike so you can get back to reliable, responsive riding in under an hour.
Key Terminology
- Throttle housing – 2‑piece plastic shell that holds the grip and cable end on the handlebar.
- Ferrule – The metal collar crimped to the throttle‑cable sheath.
- Carburetor linkage – The lever on the carb accepting the inner cable.
- Free play – Small rotational slack at the grip (1–2 mm) before the cable pulls.
Hot engines & moving parts can cause serious injury.
‑ Let the engine cool completely.
‑ Remove the spark‑plug boot before you start.
‑ Wear safety glasses and gloves at all times.
Parts
-
-
We should remove seat for better access.
-
There are two 8mm bolts holding the seat down to the frame (Picture 2)
-
Remove, them and pull up and the seat should just come off, making it much easier to access components of the throttle assembly
-
Step 1 Completed
-
-
-
Inspect the Throttle Assembly Check for visible damage to the throttle cable, grip, and housing. Look for frayed cables or sticking in the throttle twist mechanism.
-
As you can probably see this cable is pretty frayed up. So it must be replaced
-
-
-
Remove the Screw in Photo 1 with the Philips head screwdriver.
-
Slide the rubber grp off
-
Take off the throttle clamp to expose the throttle cable sheath.
-
Step 4 Completed
-
-
-
From the throttle assembly located on the engine remove the nut screw holding the cable in place (photo 1)
-
Use the screwdriver to take off.
-
Step 5 completed
-
-
-
Lay out your new throttle kit in front of you. Check to make sure you have a grip, throttle cable and clamp.
-
Take apart throttle clamp with screwdriver.(Picture 2 & 3)
-
-
-
Install the new wire onto the new throttle.
-
First insert the ferrule into its recess.
-
Step 7 completed
-
-
-
Insert the ferrule into its recess. (Pic 1)
-
Hook the barrel into the grip drum. (Pic 2)
-
Check that the cable rides in the molded channel.(pic 3)
-
Step 8 completed
-
-
-
Prepare the grip and throttle for installation on the handlebars. (Pic 1)
-
Apply a drop of thread‑locker to each bolt. Clamp the two housing halves together (Pic 2)
-
Slide the grip on (pic 3)
-
Step 9 Completed
-
-
-
Secure the throttle assembly onto the handlebars.
-
Slide the grip on; tighten the set screw. (Pic 2)
-
Step 10 completed
-
-
-
Attach the cable sleeve to the throttle assembly on the engine.
-
From the throttle assembly located on the engine place the throttle cable then tighten the screws.( Pic 2 and 3)
-
Step 11 completed
-
-
-
Adjust the Throttle Tension Ensure the throttle snaps back properly when released.
-
Adjust the cable tension if necessary, using the adjustment screw near the carburetor. Refer back to the previous step if necessary.(Pic 2 & 3)
-
To reassemble your device, follow these instructions in reverse order.
