Broke my Throttle cable

crabdance · #1 (**permalink**) 07-30-2008, 10:38 AM

Hi everyone, I broke my throttle cable somehow. I was messing with the adjustments above the carburetor trying to get more power out of the bike (which did not work). And when I was through there was no cable coming out of the carburetor end. Now I have to buy a new cable. What I'm wondering is "what did I do"? I know just enough to be dangerous when it comes to working on these things. This is a new(ish) carburetor and the last one I had I tightened up the cable and made it go faster and not bog down on hills so much. This one just broke the cable. Does anyone know what I might have done? It's something I don't want to do again. I messed with the 3 things about the carb that you can turn. and that's all.

Any help will be appreciated. If you need more info please ask.

**Norman** · #2 (**permalink**) 07-30-2008, 01:18 PM

If you pulled the end off the cable that goes into the carb you can repair it yourself. you will need to look at some of my carb posts I show how to solder on a new cable end. I make the little tubelear end by wrapping the cable with one strand of phone wire and then silver solder it. Which will take a propane torch to do. silver solder will not pull off and is easier to make a good strong connection.
tools needed propane torch
dremel with fiber cut off wheel or good strong wire cuting pliers
powered wire wheel to clean the soldered area or dremel wire wheel will work
siler solder and flux
copper phone wire
you can shorten the outter housing of the cable to suit youself if its too long the inner cable will need about 60 mm sitcking out of the outter jacket I wrap about 4 turns of the phone wire at around 45 mm from the outter cable housing end. do this with the throttle cable still attached to the twist grip at the other end or else the measurements will not work.
heat up the area to be soldered it will almost or will glow red to almost white hot apply the flux then the solder. let it cool and snip off the excess clean it up and lube it with some motor oil. your ready to put it back together
some thing to be careful about heat up only the area to be soldered I said to have 60mm of inner cable to be used the excess is so you can clamp this so your hands are free to solder. you don't have to have this much extra but it is nice if you can have a little extra to work with
pratice on an old wire first to get the hang of it

crabdance · #3 (**permalink**) 07-30-2008, 01:35 PM

I don't know think I pulled the end off of the cable off, but there is no wire coming out the end (if that makes sense). The end of the cable is still there. It just seems like the cable is stuck up inside the rubber wire. It should come out but doesn't If this makes more sense to you maybe there's something else we can do. Otherwise we can keep on going in the direction of your previous post. Let me know what you think,

thanks for the help,
john

**Norman** · #4 (**permalink**) 07-30-2008, 01:45 PM

can you find the end that pulled off? it is small but can raise jell with the engine as it goes through it but it cometimes will go through with out harm so you might have got lucky.
I'll try to find the posts on the soldering of the cable.

crabdance · #5 (**permalink**) 07-30-2008, 02:10 PM

Quote:

Originally Posted by Norman

can you find the end that pulled off? it is small but can raise jell with the engine as it goes through it but it cometimes will go through with out harm so you might have got lucky.
I'll try to find the posts on the soldering of the cable.

Thanks Norman I will go and look and see if I have the end that came off. Somehow I doubt if but I' will look anyway. Thanks a lot for your help. be back in a minute.

john

crabdance · #6 (**permalink**) 07-30-2008, 02:17 PM

I just looked and I cannot find the end to the cable. Don't know where it is. I turned it upside down when I was taking the carburetor off so I might have lost it in the grass of the back yard. If that's the case I have NO idea where it is.

crabdance · #7 (**permalink**) 07-30-2008, 10:34 PM

I just tried to solder the end of the cable that I got out of the plastic wire and there is not enough cable to work. So I am going to have to get another cable or do something else.

crabdance · #8 (**permalink**) 07-31-2008, 12:04 AM

thanks for your help Norman

crabdance · #9 (**permalink**) 08-04-2008, 10:23 AM

Well, last night I ordered a new throttle cable. Hopefully it will be here this week sometime. I'm really hating not being able to ride my bike. It's no fun. I will try making up for it when I get it fixed and do some long rides

.

crabdance · #10 (**permalink**) 08-07-2008, 08:23 PM

My cable got here yesterday and it is now on and I'm riding again. Yea!