I noticed that when I turned the throttle there was about 1/4 inch or so of slack. I adjusted it so that all the slack was removed. I haven't ridden yet, but I started to wonder if maybe the slack is intentional? I am hoping that by tightening it it will help low speed operations as I find I occasional chop the throttle when it hits the slack part. Am I setting myself up for any bad results here?
This will probably be moved to the tech forum soon, but the short answer to your question is, yes, there should be slack.
Simply, start your bike in neutral, turn the handlebars both directions fully and see if it revs. If the RPMs change significantly, you have it too tight. 1/4" slack may or may not be too much "technically" but there should be enough so it can return completely to zero when released in any handlebar position.
I can't stand throttle slop. 1/4" sounds like a lot. I adjust mine so there is about 2mm rotation of the grip before the butterflies crack open. I don't mind if the idle rpm increases slightly when the bars are moved around. Good time to also lube the cable at the throttle housing and make sure the throttle snaps closed without any binding.
BK
Slack should be 2-4 mm.
You have to be careful, there should be a little slack (1/4") is about right. If you tighten too much your throttle will not shut off....much worse than chopping the throttle at low speeds.
turn the bike on and turn the bars lock to lock, if the throttle cable is too tight especially left hand turns the throttle cable will be pulled tight and actually increase throttle. Scary shit when you learn that lesson the first time [roll]
Good luck
Thanks for the help guys. I did the turning test with no increase in RPMs but I decided to put in a couple of mm back in anyway. Taking out the extra slack has been a great help in keeping me from abruptly shutting off the throttle when slowing! :)