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Norm's 2 stroke repair center Having problems with your 2 stroke engine? Just ask Norm, he loves to tinker and troubleshoot engines

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  #11  
Old 11-20-2009, 05:06 AM
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Blakenstein Blakenstein is offline
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Default Re: Norm shortening a throttle cable

The slack is there to allow full tightening from a full closed slack adjustmen screw while at its slackest point, it will still acheive full throttle from a full closed throttle thus, as you ride your bike, in time , the new cable will strech -then the set screw be opened to compinsate. My cable allows this and am i ever glad because it was designed so that it can be cut several times, before it becomes too short to allow full CLOSED throttle -then all you have to do is cut off a bitt of housing.:/
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  #12  
Old 11-20-2009, 05:46 AM
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Default Re: Norm shortening a throttle cable

Quote:
Originally Posted by donuts31 View Post
I've used this method to make new throttle cables from brake cables instead of waiting for one to come in from a vendor.
I tired brake cable also but i found that they were too thick for housing causing lots of resistance. Ended up braking. I will use bike shifter cable and grind down little nib at end to fit the carburetor slot and then cut the cable at other end to fit throttle -then I will use Norms cable ends to attach to throttle and I just happen to have two of norms cable ends, yep, I went and made them ,they are amongst the greatest things this forum could ever have. The extra length of my "stock " cable allows me to repair it more than once if it snaps,but of course I have to have Norms cable ends and I already have them. The time and trouble it took to make them is nothing compared to the time and trouble they will save. :/
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  #13  
Old 11-20-2009, 06:07 AM
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Default Re: Norm shortening a throttle cable

I love the very end of the video......."Get on there ..You PIG!" LOL!
Those things can be frustrating!
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  #14  
Old 11-23-2009, 01:11 PM
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Default Re: Norm shortening a throttle cable

awesome norm, I always wondered how to make a new tit on the end without buying the brass ones for cable kits there a rip off!!!
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  #15  
Old 01-18-2010, 09:04 PM
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bairdco bairdco is offline
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Default Re: Norm shortening a throttle cable

why isn't this a sticky?

edit: ok, did someone just sneak in here and sticky this, or am i losing what's left of my mind thanks to a whole day of rain giving me cabin fever?

Last edited by bairdco; 01-18-2010 at 09:14 PM.
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  #16  
Old 01-19-2010, 10:50 AM
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Default Re: Norm shortening a throttle cable

you must of lost what you had it been a sticky for a while. LOL!

Some people have asked what the phone wire does or what it for?
I wrap the single strand of copper wire around the cable,one layer thick
(around 5 turns)tightly to make a sort of spiral wrapped knob which is the
replacement for the tit( ferrule) that was on the end. I apply only enough silver
solder to fill the cable and the wrapped on phone wire no need to gob on a big booger
of solder. the solder is a way of solidly attaching the phone wire to the cable
which once attached is the new end for the cable
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  #17  
Old 03-08-2010, 11:09 AM
taddthewadd taddthewadd is offline
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Default Re: Norm shortening a throttle cable

Norm, I watched the video but it was pretty blurry so I couldn't see any detail. I get the general idea of what you are doing but couldn't see a few parts. One is I think you wound some copper wire somewhere and the other is I couldn't see what the solder was for or where you put it. Is the solder acting as the little ball stopper at the end of the cable.

Do you think you could post a pic of the final product?
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  #18  
Old 03-08-2010, 11:19 AM
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Default Re: Norm shortening a throttle cable

The solder is used on the wrapped on phone wire. The solder bonds the phone wire to the cable
making the wrapped on wire the cable end.
Use just enough solder to fill in the wires.
Practice on a scrap cable to get it right. You will see how it works once you try doing it.
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  #19  
Old 03-08-2010, 02:12 PM
taddthewadd taddthewadd is offline
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Default Re: Norm shortening a throttle cable

So you wrap the wire on just the very end? like say the last 3-4 mm?
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  #20  
Old 03-08-2010, 03:40 PM
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Norman Norman is offline
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Default Re: Norm shortening a throttle cable

measure where you want the end to be wrap the phone wire around the cable for 3 to 4 mm
in length (the phone wire becomes the tit you will need for the end) silver solder the tit to the cable clean off the flux/boogers then trim off the excess length.

http://motorbicycling.com/f39/motori...build-302.html
go to permalink #17 on page #2 it shows a photo of the cable end
look closely there is a length of cable with the phone wire wrapped on it. I have a arrow pointing to the phone wire wrapped on the cable. The phone wire is not trimmed or soldered on on that length of cable. then towards the bottom right side is an example of the tit and cable end, its a short chunk of cable with an end soldered on made from phone wire.
hope that helps you.

Last edited by Norman; 03-08-2010 at 03:53 PM.
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