Twistgrip Modification for Progressive Action, Part 2

Nick Woods, Norfolk, UK, March 2008

In Part 1, I listed reasons for trying to make my Ducati ST4 more

manageable at low speed/revs, and described a simple modification
of the nylon cam/quadrant of the OEM twistgrip tube. By locating
the throttle cable nipple at a smaller radius and cutting a ramp to
lead the cable out to the original surface, the start of the throttle
action was geared-down, making throttle opening progressive
rather than linear, with the result that the bike was appreciably
easier to control.

Since this mod was carried out in the autumn and proved successful,
it was hard to resist attempting to improve it over the winter lay-up
period. The old cam quadrant was cut from the twistgrip tube,
which was then turned in the lathe to leave a circular ledge of
sufficient thickness to support the new quadrant.

The new quadrant was made from 5mm brass sheet, with an
integral full circle support, the inner diameter of which was bored
to give a close fit on the twistgrip tube. The quadrant was locked to
the tube by two small diameter screws threaded through the brass
into the nylon.

The maximum diameter of the quadrant was essentially as per the

OEM version, being as large as possible while still giving clearance
for the cable beneath the cable-guide cap. The nipple insertion was
drilled on a radius approximately 7mm less than OEM, and a
shallow vee track cut to guide the cable out to the full diameter at
approx 2/3 of its travel. Apart from knowing that 36mm of cable
inner movement was required to give the full range of the injector
throttles, the dimensions and the profile of the new quadrant were
very much suck-it-and-see.

In the course of assembling the unit I discovered that, after 25K

miles, the OEM throttle cable inner was starting to fray at both
ends. Rather than buy a complete new unit I made my own inner,
using pedal-cycle gear-cable inner made of stainless coated with
smooth plastic. There are various options for these cables. Some are
simply bare stainless wire, some have a dressing of anti-friction

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PTFE paste and the best (by Gore) have a full PTFE sheath. These
last would be the ideal, but they are expensive. I used something
similar that I had already, attaching turned brass nipples with hard
solder, and the action is very smooth.

Having assembled the twistgrip, the total rotational angle is now

77degrees, compared with 72 for the stage 1 mod, and 68 for
OEM. 13% extra rotation over the original is quite modest, but the
progressive action ensures that throttle opening is distinctly slower
over the first quarter of the range, speeds up for the second and
third quarters, and is at OEM rate for the final quarter.

On the road, my ST4 is transformed. Modulation of engine speed

as the clutch bites is extremely easy, making low-speed manoeuvres
far safer. Power-on-off-on transitions are much smoother: it is as if
all the slack had just been taken out of the final drive chain. As
before, I have greater confidence feeding the power on around
bends because I can be sure that a sudden surge will not break
traction or cause the bike to run wide.

In short, the dynamic responses have been refined to a remarkable

degree, and permit elegant progress. If I ever carried a pillion
passenger, I’m sure they would appreciate the reduction in surging.
My throttle hand and arm muscles benefit from the improved ease
of use, and I have quickly learned to apply a little more rotational
angle than the OEM unit required if strong acceleration is called for.
Best of all, the fuelling of my standard dealer-serviced bike remains
perfect, without the slightest hesitation when a tiny increment of
extra throttle is applied. Put simply, the bike is more user-friendly.

So much for DIY… It appears that a progressive twistgrip of very

similar profile and rotational range is now available commercially
for Ducatis from www.g2ergo.com of Illinois, under their Throttle
Tamer brand. That’s the route I would probably go now, if I were
starting afresh. Money well spent!

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The new quadrant profile with the cable track in red, over the old
OEM unit, stage 1 modified condition in green, original on outer
contour.

Reverse of new quadrant. Two screws just lock the close-fitting

quadrant to the nylon tube.

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Shows shallow groove to guide cable inner. Nipple inserts from
back of hole, for neatness.