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.
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We should remove seat for better access.
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There are two 8mm bolts holding the seat down to the frame (Picture 2)
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Remove, them and pull up and the seat should just come off, making it much easier to access components of the throttle assembly
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Step 1 Completed
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Once the seat is off you can see the spark plug wire.
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Step 2 Completed
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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.
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As you can probably see this cable is pretty frayed up. So it must be replaced
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Remove the Screw in Photo 1 with the Philips head screwdriver.
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Slide the rubber grp off
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Take off the throttle clamp to expose the throttle cable sheath.
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Step 4 Completed
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From the throttle assembly located on the engine remove the nut screw holding the cable in place (photo 1)
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Use the screwdriver to take off.
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Step 5 completed
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Lay out your new throttle kit in front of you. Check to make sure you have a grip, throttle cable and clamp.
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Take apart throttle clamp with screwdriver.(Picture 2 & 3)
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Install the new wire onto the new throttle.
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First insert the ferrule into its recess.
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Step 7 completed
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Insert the ferrule into its recess. (Pic 1)
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Hook the barrel into the grip drum. (Pic 2)
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Check that the cable rides in the molded channel.(pic 3)
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Step 8 completed
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Prepare the grip and throttle for installation on the handlebars. (Pic 1)
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Apply a drop of thread‑locker to each bolt. Clamp the two housing halves together (Pic 2)
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Slide the grip on (pic 3)
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Step 9 Completed
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Secure the throttle assembly onto the handlebars.
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Slide the grip on; tighten the set screw. (Pic 2)
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Step 10 completed
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Attach the cable sleeve to the throttle assembly on the engine.
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From the throttle assembly located on the engine place the throttle cable then tighten the screws.( Pic 2 and 3)
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Step 11 completed
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Adjust the Throttle Tension Ensure the throttle snaps back properly when released.
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Adjust the cable tension if necessary, using the adjustment screw near the carburetor. Refer back to the previous step if necessary.(Pic 2 & 3)
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Attach spark plug in (pic 1)
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Put seat Back on. (pic 2)
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Grip it and Rip It
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To reassemble your device, follow these instructions in reverse order.
To reassemble your device, follow these instructions in reverse order.
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York University, Team 4-8, Woodhouse Winter 2025 Membre de l'équipe York University, Team 4-8, Woodhouse Winter 2025
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