Adjustable Throttle Cable Extension, for Push Pull Cables

OVERVIEW

When you''re building a custom sand rail, a high-performance dune buggy, or a modified street Beetle, the standard throttle cable setup rarely provides the flexibility needed for a truly professional installation. The EMPI Adjustable Throttle Cable Extension (Part # AC798541) is the ultimate solution for air-cooled enthusiasts who demand precision and modularity in their linkage system. Designed specifically to interface with industry-standard Morse-style push-pull cables, this extension bridges the gap between your pedal assembly and the carburetor, allowing for a perfectly tuned throttle response. Whether you are dealing with a non-standard chassis length, a unique engine swap, or simply want the ability to fine-tune your cable tension without the headache of traditional set screws, this robust extension provides the mechanical advantage and length required to keep your air-cooled powerplant performing at its peak.

One of the standout advantages of this extension is its indispensable role in vehicles equipped with adjustable pedal sliders. In the off-road world, drivers come in all sizes, and being able to move your pedals forward or backward is a game-changer for ergonomics and safety. This kit allows your throttle cable assembly to effectively grow or shrink along with your pedal position, ensuring you always have full wide-open throttle (WOT) capability regardless of where the seat is positioned. The tool-free wing nut adjustment mechanism makes track-side or trail-side tuning an absolute breeze, eliminating the need to dig through your tool bag for a specific wrench when you just need a few more millimeters of throw. Built with the rugged durability that EMPI is known for, this component is a critical upgrade for any serious air-cooled VW project that utilizes a sleeved push-pull cable system for superior throttle control.

FITMENT

• Volkswagen Beetle: All years (When converted to push-pull cable systems)
• Volkswagen Karmann Ghia: All years (Custom applications)
• Volkswagen Type 3: Notchback, Squareback, Fastback (Custom applications)
• Volkswagen Thing (Type 181): All years
• Dune Buggies: Meyer''s Manx, Manx clones, and fiberglass tub buggies
• Sand Rails: All custom tube chassis applications using 10-32 threaded cables
• Baja Bugs: Custom off-road builds with rear-mounted engines
• General Application: Any vehicle utilizing a Morse-style or push-pull sleeved throttle cable

SPECS

• Manufacturer: EMPI
• Part Number: AC798541
• Minimum Length: 8-1/2 Inches
• Maximum Extended Length: 19-1/2 Inches
• Thread Pitch: 10-32 (Standard for most push-pull throttle cables)
• Adjustment Type: Manual Wing Nut for tool-free operation
• Material: High-tensile steel with corrosion-resistant plating
• Components Included: Extension rod, adjustment wing nut, and cable interface hardware
• Application Type: Push-Pull / Sleeved / Morse-style cables

PRO TIPS FROM THE SHOP

Tip 1: Double-Check Your Thread Engagement

When extending the unit to its maximum length of 19-1/2 inches, always ensure that you have at least 1/2 inch of thread engagement on both the cable side and the extension side. While the wing nut makes adjustment easy, the structural integrity of the throttle pull depends on sufficient thread contact. If you find yourself at the very edge of the adjustment range, it is safer to move your cable mounting bracket than to run the extension with only a few threads holding it together. This prevents the cable from stripping out under the high-stress conditions of wide-open throttle runs.

Tip 2: Lubrication is Key in Dusty Environments

Since these extensions are frequently used on sand rails and off-road buggies, the threaded portions are often exposed to dust, silt, and sand. We recommend applying a very light coat of dry graphite lubricant or a thin film of anti-seize to the threads. Avoid using heavy greases that can attract sand and turn into a grinding paste, which will eventually gall the threads. A clean, lubricated thread ensures that the wing nut remains truly ''tool-free'' even after a long weekend in the dunes or out on the trail.

Tip 3: Lock It Down for High-Vibration Use

While the wing nut is designed for easy adjustment, the high-frequency vibrations of an air-cooled VW engine can sometimes cause manual adjusters to migrate over time. Once you have found the ''sweet spot'' for your throttle throw, we suggest adding a 10-32 jam nut behind the wing nut or using a small dab of medium-strength (blue) thread locker. This provides an extra layer of security, ensuring that your idle speed and wide-open throttle settings remain consistent during aggressive driving or over rough washboard terrain.