Cracks in throttle cable cover near handgrip on M1100 EVO

[SDRider]

So, this morning I gear up to ride my Monster 1100 EVO to work, I start it up, get on and as I'm pulling out of the garage and accelerating down my street it feels like I have a lot of play in my throttle.  My mind starts trying to figure out what could cause this and what I should do about it.  I come up to a stoplight near my house and blip the throttle a couple times while looking at the housing on the bar and notice the cover is flexing up and down and there are some hairline cracks in the cover.  This is the cover that goes over the cable housing for the throttle.  Not the grip itself, just the cover that houses the cable at the grip.  It's an L shaped piece of hard polished plastic that helps route the throttle cable.  It is held on with 2 screws.

This is the part.


This is where it goes.



I decided that it probably isn't a good idea to ride with it like this so I turned around and rode home to change gear and hop in the cage to go to work.

I removed the cover and did some searching online when I got to work and found out this piece only costs $6 and Pro Italia showed they had one in stock so I ordered it.  I stopped by my local dealer on the way home to see if they had one in stock and to show them the piece.  Of course, they've never heard of this happening before. :rolleyes: They say that every time something goes wrong with my bike though.

Bike has never been down, never had any issues with the throttle before, no binding or anything.  It was 112 degrees on Friday when I rode to work last so I'm wondering if heat might have been a factor.  I had a cover on the bike at work though and it rode fine when I rode it home in the afternoon.

Anyone else had this happen?  I searched and didn't find anything.

[Slide Panda]

Really I've never heard of that either. But a likely cause is that the screws were over tight? Can't really see where it's cracked in the photo. That's not a structural or stressed part so even the cracks in it don't matter much as is.

[SDRider]

I forgot to mention that I do have the G2 Throttle Tamer on my bike.  I've had that on for almost a year though and haven't had any issues with it.  I'm running the 100 cam which is identical to stock.  I had the 200 cam for a few months but wanted the original throttle responiveness so I changed that one out probably 4-5 months and a few thousand miles ago.  Never felt any binding or issues with the throttle until yesterday when I noticed the cracks.

[SDRider]

Really I've never heard of that either. But a likely cause is that the screws were over tight? Can't really see where it's cracked in the photo. That's not a structural or stressed part so even the cracks in it don't matter much as is.

The cracks are on the top of the housing right where the cable routes before it makes that left hand bend.  You can see them in the photo (they are just off center in the picture of the cover on that smooth curved part of the cover-probably the thinest part of the cover really).  They are nowhere near the screw holes and I haven't had this cover off the bike in months.

[Slide Panda]

While annoying and I agree it should not have happened - it's not a critical failure and won't effect the bike in the short term

Is that the stock throttle tube though? It appears to be metal and all the stock duc tubes I've seen are plastic. If it's an aftermarket tube - that might be the source of your crack. So say the cover moves when you twist the throttle. Obviously the cam/cable are making contact. I'd been looking at an aftermarket modification like that vs some mystery cause of spontaneous cracks in plastic

[SDRider]

While annoying and I agree it should not have happened - it's not a critical failure and won't effect the bike in the short term

Is that the stock throttle tube though? It appears to be metal and all the stock duc tubes I've seen are plastic. If it's an aftermarket tube - that might be the source of your crack. So say the cover moves when you twist the throttle. Obviously the cam/cable are making contact. I'd been looking at an aftermarket modification like that vs some mystery cause of spontaneous cracks in plastic

It is metal and it is a really nice part, much better than the cheap plastic stock unit.  G2 throttle with the stock size cam.  It never seemed that it was binding at all but it obviously is contacting the cover and moving in the area where the cracks are.  I'm going to see if it contacts it when I get the new cover and see if I need to file down a bit of the cam or the throttle tube.  Not really too keen on doing that but if it fixes the problem then I'll do it.

The cover does route the throttle cable even with the stock tube so there must be some contact there too.

[Raux]

I would bet if you check the clearance on the larger cam you were running you were putting stress on the part.