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Making your own throttle cables

B

bradlys

Member
Joined
Apr 1, 2018
Location
San Carlos
Moto(s)
07 SV650S; 93 CBR900RR
Anyone tried doing this? I'm looking into making my own throttle cables. (Both sides have the cylinder at the end that you slide in) However - I'm most worried about getting the correct cable and then finding the correct ends.

As it stands, both of my throttle cables snapped recently and I need to replace the steel cables themselves. (They're old) However - I rather not spend $60+ on pre-made cables... Thus - make my own.

I've been trying to see more about what people use to solder them in but I don't see much information other than to melt some lead. Which doesn't work well for me since I don't have any lead and everyone wants you to buy a big ingot of lead. :/

Thoughts?? Better ways to solder the wire to the little metal cylinder? There must be a way...
 
I've made my own throttle cables out of necessity... you see RC45 are so rare
there are only 56 in all of North America so no aftermarket company will ante up
such low numbers... Not even K&N will ante up a filter... I had to make my own...

I machine a brass cylinder and captured it by brazing a ball onto the cable... its
stronger than solder...
 

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bradlys said:
Anyone tried doing this? I'm looking into making my own throttle cables. (Both sides have the cylinder at the end that you slide in) However - I'm most worried about getting the correct cable and then finding the correct ends.

As it stands, both of my throttle cables snapped recently and I need to replace the steel cables themselves. (They're old) However - I rather not spend $60+ on pre-made cables... Thus - make my own.

I've been trying to see more about what people use to solder them in but I don't see much information other than to melt some lead. Which doesn't work well for me since I don't have any lead and everyone wants you to buy a big ingot of lead. :/

Thoughts?? Better ways to solder the wire to the little metal cylinder? There must be a way...
Click to expand...
Fishing weights are a good source for lead but then you still need to fiddle and fashion a casting mold :(

auntiebling said:
i've done a clutch cable, and would have zero qualms making my own throttle cables if i need to.

paste flux helps, fray the cable a little so the solder forms a wedge between the strands

http://www.chopcult.com/forum/showthread.php?t=166
Click to expand...

I like this :thumbup. If I had to make a custom cable this looks like a great option.

Apparently there is premade stuff for sale. Googled "solderless cable nipple" and found this https://www.banggood.com/Motorcycle...AWASAKI-HONDA-p-1099943.html?cur_warehouse=CN. Cheap! Not as confidence inspiring as soldering but should be good enough.
 

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RVFRick said:
Fishing weights are a good source for lead but then you still need to fiddle and fashion a casting mold :(



I like this :thumbup. If I had to make a custom cable this looks like a great option.

Apparently there is premade stuff for sale. Googled "solderless cable nipple" and found this https://www.banggood.com/Motorcycle...AWASAKI-HONDA-p-1099943.html?cur_warehouse=CN. Cheap! Not as confidence inspiring as soldering but should be good enough.
Click to expand...


I have something similar I found off of amazon. I havent used the parts but the set screw barrels I dont think I'd trust for anything but an emergency, and the cables themselves are pretty small. Plenty strong for emergencies, maybe a good long time even, but overall it's a little dainty for motorcycle use. I'm fairly sure it's meant for bicycles

General comment: brass screws from the Usual Suspects can be cut up for the barrels. Ideally the threadless shoulder section.
 
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I've had to make my own cables for some projects, but I'll take pre made cable assemblies over DIY stuff every time. I have a Nicopress for couplers, and I use paste flux and solder for the ends. If you're going for high load situations, I use brass rods from the welding store instead of tin solder.
 
Don't know which bike you need cables for but Motion Pro has the SV ones for $35 and the CBR ones for $45.
 
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