Shortening clutch and throtle cables

[ridesolo]

I'm working away at reassembly and realize that my clutch and throttle cables are now about four inches too long. Is there a relatively fool proof method to shorten them yourself or, for the sake of "being sure" would it just be best to order custom made?

 

[iatethepeach]

My clutch cable really ought to be a few inches shorter (a result of my recent engine swap). I just wrote to Motion Pro about having one custom-made: $70 for the basic black-vinyl option. It would be nice, but at least in my case, a few strategically-placed zip ties are a good alternative.

 

[Streetfighterkz]

I think Ichiban Moto or something like that has a video on Youtube, along with other people, about shortening cables. I shortened my choke cable on my Cx500 using that video as a guide. Might want to hop on there and search.

Later, Doug

 

[teazer]

One way is to go to Flanders Cables on-line and find the correct end fittings. It's easy to cut off one end of the inner with a suitable dremmel cut-off wheel. Remove the inner and cut the outer sheath to length. Cut the same amount off the inner cable (less the amount that you already shortened it by cutting off the end).

Test fit the cable to be sure that both inner and outer are now the appropriate length, then clean up the inner cable and solder on a new end fitting. It's easier with a solder pot than with a soldering iron, and don't forget to splay out the cable end like a bird's nest, to form a wedge inside the new nipple (end fitting).

If that sounds like too much work, order one from Motion pro or similar supplier.

My preference is DIY. YMMV.

 

[ridesolo]

I think Ichiban Moto or something like that has a video on Youtube, along with other people, about shortening cables. I shortened my choke cable on my Cx500 using that video as a guide. Might want to hop on there and search.

Not sure how to reply to this. I've used YouTube many times for many things and brother Ichiban is a fine human being whom it would be my pleasure to someday meet for coffee...

One way is to go to Flanders Cables on-line and find the correct end fittings. It's easy to cut off one end of the inner with a suitable dremmel cut-off wheel. Remove the inner and cut the outer sheath to length. Cut the same amount off the inner cable (less the amount that you already shortened it by cutting off the end).

Test fit the cable to be sure that both inner and outer are now the appropriate length, then clean up the inner cable and solder on a new end fitting. It's easier with a solder pot than with a soldering iron, and don't forget to splay out the cable end like a bird's nest, to form a wedge inside the new nipple (end fitting).

If that sounds like too much work, order one from Motion pro or similar supplier.

My preference is DIY. YMMV.

Thanx for the comments and advice. My preference in most things is DIY as well, and I usually have a good amount of confidence, sometimes too much(!), in my abilities, I've been hesitant to tackle shortening cables out of a desire to not find myself stranded on the side of the road.

I'll check out Flanders. I've got extra cables so I can probably give it a practice shot. I don't have and have never worked w/ a solder pot, but am very comfortable w/ a soldering iron. I understand that it's critical to get the cable completely clean for there to be any hope of getting a good solder joint. Suggestions on that? How about keeping the cable from fraying when you cut it? I've never been hugely successful attempting that in the past even w/ a Dremel.

 

[J-Rod10]

I use 50/50 lead/tin solder, and generally make my own fittings.

 

[irk miller]

+1

 

[adventurco]

I have a ton of ferrules and length of cable from Flanders. I bought a solder pot and a stick of 50/50 solder with Ruby Paste flux.

Flare the strands of the cable after the ferrule is on. Flux the end of the ferrule and cable end, heat on solder pot to burn it off. Dip in melted solder in pot for a couple seconds. Done.

Be careful not to let the flux get onto the cable past the ferrule or you will have a 1/2" section of very stiff cable which is not ideal in some situations.