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Apparently, the throttle house housing/twist grip was redesigned in '21 along with the throttle cable, which is now an $80 part.
...and also pretty hard to source.
Is anyone aware of any aftermarket replacements or such? I really need one for my son's '22.
I run the trex throttle and cable on all my kids 65’s. More expensive then what your looking at but it’s night and day smoother then oem and the throttle is o ring sealed so dirt can’t get in.
KTM has a really weird history with throttle housings and throttle cables on 2-strokes..
Looking at the diagrams, it appears the 65 had a nice housing with a pulley up to 2020 and then went to a crappy housing with no pulley in 2021, similar to the 2017-2020 big bike housing where there is just an elbow bend and a crap ton of drag.
I suspect the older 2020 housing and cable will bolt right up on the 21-22. I'd probably get that complete setup or the Trex setup.
The 85Sx is whole nother story of weird stuff KTM did with throttles and cables.
I think the parts diagram for the '21+ is misleading as it depicts the same throttle cable as previous years(part #s obviously differ).
The new design has the pulley as a component of the throttle cable itself versus inside the throttle/grip assembly as in the older gens.
2021+
The redesign also has an all metal housing.
Pre-2021:
OK, that clears things up a bit. So that 2021+ housing is the same on the 65, 85, and all the big 2-strokes 2021+ (all same part #). They all use a cable with the pulley integrated on the cable, but all 3 are different part numbers, likely length of the cable being the main difference. Note, since they all use the same housing, grips, cam, etc, the pull is really quick on the little bikes and pretty long on the big bikes.
Here's where things get weird. About a year ago, my buddy ordered a new cable for a 2021 85SSX as they can fray by the pulley. When the cable came, in place of the pulley it had this weird adapter elbow thingy that fit in the space in the housing intended for the pulley. There was nothing in the diagram or otherwise indicating you'd get this replacement/superceded part. Ripoff!!! Way more drag than the original cable with pulley. So, we ended up using a 125 cable on that bike. Bolted right up and was just a tad longer.
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Was the 2021 85SX cable he ordered OEM?
Yes. Like I said, he just ordered normally as you would, through RMATV. Where the blue pulley should have been the plastic tip of the cable had an elbow and there was like an extra plastic "leg" molded to that elbow to make it fit snugly in the circular area of the housing where the pulley should go. Felt like crap compared to the pulley version also. I took a pic of it at the time I'll have to try to dig up.
I just ditched the stock set-up on our '22 85 when the cable frayed at the pulley. I installed an older Domino housing I had left over from our 65 with a $10.99 Motion Pro cable from the '17 85 and it's much smoother than the internal pulley system of the '22.
the crappy replacement KTM 85SX OEM cable....
C'mon!!
There must've been a parts or packaging/labeling mix-up of some sort with that cable. That could not have been intended to be a genuine OEM replacement...right?
That's a bush league set-up right there. I would not send my kid out there with that.
That more closely resembles the stock PW50 throttle assembly than it does these pricey Austrian minis for cryin out loud!
This had me curious so I did some looking. The '22 has one part number for the throttle housing and for the cable. The '21 has the same PN for the housing but a different cable PN. The '20 has the same cable PN as '21 but a different housing PN. Weird stuff.
Serious as can be. This is the OEM part KTM sent. It definitely wasn't a mix-up because it's obvious this was purposely created to fit into that circular area of the housing. Like I said, it felt like crap so we put a 125 cable with the blue pulley in there. I'm guessing/hoping that maybe this was due to covid supply chain issues at the time and hopefully KTM is not still shipping these. We haven't needed to order any more since.
Isn't it crazy? For comparison, Honda used the same throttle housing on every full size 2-stroke they made from like 1986 to 2007 but KTM changes them like underwear and always seems to come up with baffling ideas.
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