emdude
Member
The throttle cable that came with my engine kit was entirely too long for the "clean" installation I wanted. Getting the correct cable length on the clutch was of course no problem. So here's what I did to shorten the throttle cable:
I removed the throttle cable completely from the carburetor.
Lined up the the black outer cable exactly with the top of the carburetor once I was satisfied this would be the correct final length.
Marked that position on the the black throttle cable.
Removed the entire throttle cable from the bike.
Cut off the little nipple that goes into the slide of the carburetor and removed the inner wire cable from the black sleeve completely.
Cut the outer black sleeve to the marked position.
Reinstalled the inner wire into the black sleeve...and made a new nipple. That's the fun part as follows:
I wrapped some 22 AWG bus wire tightly around the cable for about 5 turns. Cut the edges of the bus wire and massaged them cleanly and tightly into place. The bus wire was now tightly wrapped around the cable.
Then I took the piece of the black outer sleeve I had cut off and lined it up exactly with the end of the wire cable. Now the bus wire wrap was slid into position at the OTHER end of the black sleeve I had cut off since I needed to remove exactly the same amount of inner cable as I did outer sleeve.
I then simply soldered the bus wire wrap onto the cable at the correct position as determined above and with VERY LITTLE solder. Just enough solder to melt into the buss wire wrap and to flow into the cable. Tested for strength and cut off the extra cable behind the "new" nipple.
This kind of thing was much easier when I was a kid because you could buy the round nipple ends as they go into break levers and as they are in the twist throttle assembly that were mounted to the cable with a worm screw. Haven't been able to find those at any bike shop here.
I hope I've attached some photos that will show some detail. Throttle 1 shows the bus wire wrap slid into position with the cust sleeve next to it before soldering into position.
Throttle 2 shows the "new" nipple after soldering and cutting the cable.
And yes, that is a vintage HH Scott 299C tube amp undergoing refurbishment that the parts are sitting on.
As I said, I used 22 AWG bus wire because it's what I had. You could use anything that fits really. Just wrap whatever wire you may find around the cable and check to see if it will work in the slide once you soldered it.
I removed the throttle cable completely from the carburetor.
Lined up the the black outer cable exactly with the top of the carburetor once I was satisfied this would be the correct final length.
Marked that position on the the black throttle cable.
Removed the entire throttle cable from the bike.
Cut off the little nipple that goes into the slide of the carburetor and removed the inner wire cable from the black sleeve completely.
Cut the outer black sleeve to the marked position.
Reinstalled the inner wire into the black sleeve...and made a new nipple. That's the fun part as follows:
I wrapped some 22 AWG bus wire tightly around the cable for about 5 turns. Cut the edges of the bus wire and massaged them cleanly and tightly into place. The bus wire was now tightly wrapped around the cable.
Then I took the piece of the black outer sleeve I had cut off and lined it up exactly with the end of the wire cable. Now the bus wire wrap was slid into position at the OTHER end of the black sleeve I had cut off since I needed to remove exactly the same amount of inner cable as I did outer sleeve.
I then simply soldered the bus wire wrap onto the cable at the correct position as determined above and with VERY LITTLE solder. Just enough solder to melt into the buss wire wrap and to flow into the cable. Tested for strength and cut off the extra cable behind the "new" nipple.
This kind of thing was much easier when I was a kid because you could buy the round nipple ends as they go into break levers and as they are in the twist throttle assembly that were mounted to the cable with a worm screw. Haven't been able to find those at any bike shop here.
I hope I've attached some photos that will show some detail. Throttle 1 shows the bus wire wrap slid into position with the cust sleeve next to it before soldering into position.
Throttle 2 shows the "new" nipple after soldering and cutting the cable.
And yes, that is a vintage HH Scott 299C tube amp undergoing refurbishment that the parts are sitting on.
As I said, I used 22 AWG bus wire because it's what I had. You could use anything that fits really. Just wrap whatever wire you may find around the cable and check to see if it will work in the slide once you soldered it.
