Shortening clutch and throttle cables

Discussion in 'Motorized Bicycle General Discussion' started by meowy84, Jun 27, 2012.

  1. meowy84

    meowy84 New Member

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    How many of you have shortened your clutch and throttle cables? The frame on my bike is smaller and so these two cables seem a little long compared to my brake cables. It's not a matter of functionality but rather I want the cables to be neat in appearance with no huge loop over the handlebars.

    So, that being said I removed the crimped tip from the clutch cable and cut the cable housing a little and cut the cable as well. That's fine BUT the problem is the throttle cable since it has the 'ball-ends' on both ends of the cable so not so easily shortened. Any suggestions or maybe I should just leave it alone.

    Comments, pics, tips and suggestions welcomed. :)
     
  2. Hoze513

    Hoze513 New Member

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    Go to Norm's 2 stroke repair section. He has instructions on How to make throttle cable shorter.
     
  3. Longshot270

    Longshot270 New Member

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    I just cut my throttle cable near the handle end and threaded it through the thumb shifter that came with the choke. With how hot it is over here I never use the choke so it was just another cable getting in the way...now I've got a properly lengthened throttle AND cruise control.
     
  4. meowy84

    meowy84 New Member

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    Thanks for the info guys. :)
     
  5. nightcruiser

    nightcruiser New Member

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    I changed from flat mountain bike bars to upright BMX style bars this year so I had to completely re-cable my bike, it worked out really great for me...
    First of all, you need to make a nice clean cut on the cable housing without pinching or crimping it, otherwise it will wear the inner cable. This can be kinda hard to do with regular side cutters, I purchased a Park cable cutting tool that does a nice job, it has rounded jaws that are designed to cut cable housings cleanly. I use the same tool to cut the inner cable, it does it well without fraying.
    As for the ball end on the carb cables, I just made a new ball end in the position for the shorter cable and then cut off the original ball end. Making a new ball end (for the carb side) is easy, just take some thin solid wire (like telephone wire) and wrap the (bare) wire around the cable a few times where you want the ball end to be located, then take a soldering iron and solder the wire in place on the cable leaving a ball of solder about the size of the original ball end. You can size the ball end either with heat or you can use hand tools to cut/file it into proper shape.
     

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