Throttle cable rebuild help

[dingy]

I am looking for a source of a tool/kit to be able to change out the ends on a 1st gen throttle cable.

 

I need to be able to reattach the small round lead barrel on the end of the twisted cable. I have a local source for the cable, dirt cheap, but not at the right lengths or end styles.

 

I need to do some tweaking to at least the carb end pull cable. It would also help if I could modify the choke & vboost cables.

 

I have found a place online, but they are in England. Not out of the question, but a domestic source would be nice.

 

http://www.venhill.co.uk/Cable_kits_and_components/UNIVERSAL_CABLE_KITS/VWK003_WORKSHOP_THROTTLE_CABLE_REPAIR_KIT.html

 

It seems like there should be a crimping style tool to attach the ends, but haven't found one.

 

 

Gary

[bkuhr]

Gary,

I have an aircraft electrical pin crimping tool. It has 4 opposing crimp pins that move toward center as handle is squeezed.

 

Only problem is the largest diameter crimp looks to be 1/16 inch(for a pin with 12awg wire), gets very small from there, and 1/16 may be too small for you application

 

Also have seen simular ferrells at Lowes in the wire and chain and thimbles. Dont believe I have seen any small enough for throttle cable thou, may check small engine/lawn mower repair shop for thimbles, and maybe tool.

 

I also use at work a hex crimp tool for RG58 coax. The coax center pin crimper would be about the size you are looking for. simular item I use http://www.cablesforless.com/p-667-crimp-tool-hex-ratchet-rg58-rg59-rg62-rg6.aspx, the 3rd hole from the end is the center pin crimp

Edited April 9, 2011 by bkuhr
more info

[SaltyDog]

I have bought various items through these guys in the past and they stock a wide selection of motorcycle parts. Check out the link http://www.flandersco.com/FlanCableSearch.html for the cable making/repair parts.

 

Hope this is helpful...

[dingy]

I have bought various items through these guys in the past and they stock a wide selection of motorcycle parts. Check out the link http://www.flandersco.com/FlanCableSearch.html for the cable making/repair parts.

 

Hope this is helpful...

 

 

This site has a lot of items, but the cable end is not one of them, at least not an exact match.

 

They also indicate some of the cable ends are a solder connection. I have always been under the impression that solder is not a good mechanical connection. The Venhill site at one point mentioned center punching end, then soldering.

 

Rick Butler sent me the picture attached that is what I am going to try to do with the throttle pull cable at this point. It seems like a fairly straight forward solution. I picked up a split roll pin that the throttle end will slip into. Need to braze a washer to bottom of roll pin to form a perch for the throttle cable then fab up a bracket between the carbs to attach roll pin to.

 

Still leaves me with a snug choke cable mounting point and the desire to be able to extend the vboost mount range.

 

Gary

 

 

Edited April 10, 2011 by dingy

[Keemez]

Would soldering a connection be out of the question? Not sure how well that would hold up to area heat.

[dingy]

Would soldering a connection be out of the question? Not sure how well that would hold up to area heat.

 

Solder won't melt till around 600F. The area I need to redo cable ends is in the middle and rear of carb rack. It shouldn't see anything in excess of 180F. And this is a high guesstimate.

 

Gary

Edited April 10, 2011 by dingy

[dingy]

Gary,

I have an aircraft electrical pin crimping tool. It has 4 opposing crimp pins that move toward center as handle is squeezed.

 

Only problem is the largest diameter crimp looks to be 1/16 inch(for a pin with 12awg wire), gets very small from there, and 1/16 may be too small for you application

 

Also have seen simular ferrells at Lowes in the wire and chain and thimbles. Dont believe I have seen any small enough for throttle cable thou, may check small engine/lawn mower repair shop for thimbles, and maybe tool.

 

I also use at work a hex crimp tool for RG58 coax. The coax center pin crimper would be about the size you are looking for. simular item I use http://www.cablesforless.com/p-667-crimp-tool-hex-ratchet-rg58-rg59-rg62-rg6.aspx, the 3rd hole from the end is the center pin crimp

 

 

The stock cable ends on the 1st gen cables I have are .232" dia & .313" long with .060" dia wire. This is on carb end. The throttle junction box end is a bit narrower at .158" long.

 

I haven't seen a matching part yet on a web site.

 

Choke & vboost cables are different, don't have them in front of me.

 

The stock cable wires do not appear to go through the end. And I see no tooling marks or solder indications.

 

Gary

[bkuhr]

The stock cable ends on the 1st gen cables I have are .232" dia & .313" long with .060" dia wire. This is on carb end. The throttle junction box end is a bit narrower at .158" long.

Gary

 

Don't think my crimper will help ya-sorry

Went and checked against spark plug wire gage, with largest setting of crimper and pins closed, leaves a gap between .06 and .08in, about .070.

I think your .232 dia ends will go into tool, but .07 crimp on .06 wire would almost completely pierce your new cable ends rather than just crimp then.

 

Did read a couple forums on google, seems most factory ends are molded lead. Maybe make a ceramic mold then pour lead onto cable ends? BTW, I have bunch of Pb/Sb(lead/antimony) from old lead telephone cables.(pretty solid compared to plane lead)