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I have had this problem for quite a while. It seems that no matter how well I try to adjust the throttle travel, it never seems like quite enough. If I mash my foot to the floor it doesn't quite open the throttle blades all the way and if I take a tiny bit of slack out, it wont return all the way. I need about 1/8" more pull at the pedal but there does not seem to be an easy way to adjust this with the stock cable and pedal. I am running a Holley carb with a Holley throttle cable bracket that gives me plenty of adjustment. Any have similar issue? I think if I moved the connection point a little closer to the center of rotation on the carb bracket I may get a little more rotational distance out of my fixed linear travel.
Check out the end of the cable at the accelerator pedal. The button-end on that cable fits into a little receiver at the pedal linkage. With the car OFF, pull lightly on the end of the cable and see if there is any "slack" between that cable end and the receiver. If there is, that is 'dead space' that the throttle cable has to absorb before there is ANY movement in the carb throttle linkage. An 'alternative' fix for that kind of problem is to put some kind of spacer/gap-filler between the cable end and that receiver so there is no slack in the system. I experience a similar issue and made a ball of JB Weld stick epoxy to put around the cable strand and next to the cable end piece. Let it harden overnight and, voila', no more linkage problem and secondaries opened completely. Worked for me...can't promise that'll fix your issue.
The pedal arm assembly is basically a pivot. When you bend it in such a way as to move the pedal side up away from the floor, you effectively have more rearward movement at the top pulling the cable..
Whatever you do to repair this be very careful..it may be that the fix makes the throttle plates stick open if you jam the throttle to the floor..I got some plush goofy floor mats that look nice but jam up under the gas pedal at times..from the PO..I even cut out the section under the pedal..it jammed on me this morning..it maxed out third gear before I could get it loose..scared the poop out of me..just sayin..be careful..maybe contact holley for advice or different brackets..idk..I would hate to hear something bad happened..needless to say I am in the market for new floor mats..the one under my foot ended up flying out the roof of my car after I changed I shorts!
Thanks for you response but I had to chuckle today when I checked out the Corvette service manual just to get an idea of where the bolts were before I stuck my head up under the dash. It appears that the throttle cable also has to be completely removed with the pedal assembly as well. No big deal but what made me laugh was how this reminded me of Haynes manuals.
"to increase cable travel, simply bend accelerator rod assembly"
"before preceding, see chapter 12 (Engine removal)"