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Part Number 01-0094 is supposed to fit the 2008 KLX450R, and the description says it is 1MM smaller in diameter. In fact, the throttle sleeve pulley is actually much bigger round than OEM and thicker too. This part does not fit the KLX450R throttle cable housing.
Throttle sleeve fitment
The best solutions
Hello Mark,
The 01-0094 throttle tube is a direct replacement for the 46019-0018 throttle tube. All of the functional dimensions are identical, with the exception of the reel being slightly smaller in diameter, which will have no impact on the installation of the tube. I checked fitment myself with a stock throttle housing and a 46019-0018 tube compared to a 01-0094 tube. You should have no problems. The only possibility I can think of is you got a mispackaged tube. There is a very good image of the tube here: http://www.motionpro.com/motorcycle/partno/01-0094. Please compare that image to what you have. If yours is significantly different, call 650-594-9600 and someone can assist you in getting the proper tube.
The 01-0094 throttle tube is a direct replacement for the 46019-0018 throttle tube. All of the functional dimensions are identical, with the exception of the reel being slightly smaller in diameter, which will have no impact on the installation of the tube. I checked fitment myself with a stock throttle housing and a 46019-0018 tube compared to a 01-0094 tube. You should have no problems. The only possibility I can think of is you got a mispackaged tube. There is a very good image of the tube here: http://www.motionpro.com/motorcycle/partno/01-0094. Please compare that image to what you have. If yours is significantly different, call 650-594-9600 and someone can assist you in getting the proper tube.
Chris V