In order to enjoy riding a motorcycle, not only do necessary functions have to work smoothly, but also the rider and motorcycle have to be able to "communicate" at a high level in order to enjoy riding. One of the most important factors is the condition of the cables or wires that operate the various functions. If you have new parts, you can replace it, if not, you can fabricate it. If you want to stick to the manufacturer's OEM cable even if it is ragged, it is essential to repair it to get reliable operation. Here, let's try to repair various cables in a case study.
Repairing broken and peculiar cable outers
Modern throttle cables have a double-layered outer structure where it rubs against the motorcycle body, but many old cables had a simple structure even with genuine manufacturer parts. In addition, damage may occur in a different area than the manufacturer intended. In such a case, you can insert a tube to reinforce the outer cable and glue it. Alternatively, a thick heat-shrinkable tube can be used to reinforce the outer cable by passing it through the area to be reinforced, then heating the tube with a heat gun to shrink it.
Replace only the inner while keeping the outer.
During the overhaul and cleaning maintenance of the throttle pipe, a frayed inner cable was found. In such a case, it is possible to replace the inner cable with a modern part that is flexible and does not stretch easily, while keeping the outer cable intact. In this case, I made the inner cable myself using stainless steel cable and Tyco material.
"Reproduction of dimension ratio" is extremely important.
Before you pull out the cable that is about to break, be sure to measure the dimensions of the inner and outer cables. If you get this ratio wrong, you will end up with a lot of trouble later on. For example, if the inner cable is too short, it will not be possible to adjust the play within the range of the adjuster fittings, and if it is a throttle, it will not be possible to maintain idling, and in the worst case, the engine will run at full throttle. That's what's going to happen. In order to avoid such a situation, it is important to check the current cable play. In particular, strictly measure the dimensions from the end fitting of the outer cable to the end of the take-up tycoon, and manufacture a new inner cable reflecting the measured dimensions. When cutting the inner cable, use a wire cutter instead of nippers to prevent the wire end from being pinched.
Setting up is important for wire stopper soldering
After you cut the wire according to the measurement, pass the wire through the tycoon (in this case, the sleeve on the cab side), and pinch the end of the wire with nippers so that the end of the wire opens up. Next, put the wire back carefully so that the end of the drum sleeve matches the end of the wire. If you make a mistake, the wire will fall out of the sleeve, so just be careful. Once the wire end is aligned with the sleeve end, apply liquid solder flux to the wire stopper + wire (about 10mm) before the soldering process. It is best to submerge the cable end in the flux in a container to ensure that the work proceeds properly.
Jiggle using solder pod
I used an electric device called "solder pod" to melt solder, but similar work can be done by putting cut solder in a metal container for making jelly and scorching the jelly container with a gas burner. When working, it is necessary to set up firmly so that the container does not roll over before practicing the work. After dipping the tycoon and wire in liquid solder flux (for stainless steel), submerge them in the solder pod. When the melted solder soaks in, pull up the wire and soak it in hard oil (gear oil). This procedure completes the soldering of the tycoon, but you should be able to learn the trick by repeating the operation.
- Point 1: Outer cable chafing and damage can be repaired and reinforced with thick shrink tubing.
- Point 2: When the condition of the outer cable seems to be good and the inner cable is about to break, it is possible to repair it by replacing the inner cable.
- Point 3: Because the wire will come off if it fails in the solder fixation, it is necessary to confirm whether the wire is fixed firmly by clamping the tycoon in the vise after fixing it and pulling it.
With modern motorcycles, it's easy to buy genuine parts. However, this is not always the case with older models. The definition of a "low model year" depends on the sensibilities of the individual rider, but even for popular models introduced in the 1990s, the "stock of genuine manufacturer parts" has dwindled considerably. What? Even the 90's models. But if you consider that 2000 model is already more than 20 years old, 90's model is old enough, and 70's and before model is called vintage.
For us motorcycle owners, we simply want to keep riding the models that appeal to us, regardless of their age or the passage of time. For manufacturers, however, this Sumiwake has become more apparent than ever before. In fact, over the past few years, there have been a number of parts that have been discontinued which means that they are effectively obsolete.
In such a situation, we would like to strongly recommend "stocking genuine repair parts" to riders and Sunday mechanics who want to enjoy their beloved motorcycles for a long time. One example of this would be the various cables (wires). In some cases, special parts from third parties are available for popular models. However, not all models have external parts, and even if a model is popular and beloved by you, it is not always appreciated by others. In the past, I have been in charge of full restoration and semi-restoration of various models, and unexpectedly, it is difficult to find parts for various cables.
Here, we are practicing adding support to the outer cable and repairing and regenerating the inner cable that was about to break. When you notice any problems, it is extremely important to take action as soon as possible in order to prolong the life of the component. For example, by reinforcing the outer cable, the direct rubbing of the outer cable was eliminated, and by using a modern and flexible stainless steel wire for the inner cable, the throttle feel became much lighter and the return was smoother. By understanding the importance of this kind of work, we hope you will be able to make your motorcycle's life more fulfilling.
