Jump to content
Sign in to follow this  

How To Rebuild Control Cables


ronbuell

Last year I had some bad luck as I was working on my bike and found a broken throttle cable. Yamaha wanted like $40 for a new set, (and didn't have them in stock anyway) and I wanted to save the ride that day, sooooo, here goes. NOTE: I own a MIG welder, so this was easy.

I went to the hardware store and found some round steel rod of approximately the same size as the end that came off my cable. The I took a 4" angle grinder with cutoff wheel and cut a slot for the cable to slide into. Taking the MIG, I grounded the rod, and set the heat and feed down slightly from a thin metal setting. I tacked the end of the cable first, check the position and then hit it again in the slot. Then I smoothed off the weld with the cut off wheel and cut the rod off at the appropriate length to fit the throttle wheel on the carb. All I had to do then was adjust the slack to install the cable and I was done. That was last year and the cable is still working fine.

Since then, I've also been able to repair clutch cables in the same manner. AND... I've found a source for new inner cables:

http://www.jagwireusa.com/index.php/products/mountain/499

My local mountain bikes store carries these and for less than $5.00 I can get a new inner cable and simply weld on a new end once cut to length. It's a great way to save money in these tight times!!

Ride hard, reduce your cholesterol 30 points !!!

Sign in to follow this  


User Feedback

Recommended Comments

There are no comments to display.



Create an account or sign in to comment

You need to be a member in order to leave a comment

Reply with:


  • Similar Content

    • By ThumperTalk
      Each footpeg is cast from 17-4 stainless steel, given a solution-annealing treatment, and age-hardened for superior strength
      Width (57mm) and length (90mm); slightly convex platform for better boot positioning and grip when leaning forward or back
      Dual-plane teeth provide traction without the stuck feeling
      Available with 1/2 rear offset to allow more space
      Use your OEM springs, unless otherwise noted in application chart
      Made in the U.S.A.
    • By ThumperTalk
      Built-in ergonomics; adjustable grip, height and setup
      Electromagnetic-polished patented system
      Allow both standard and lowboy setup with reversible collar insert with each peg; collars may also be purchased separately to take footpegs from one make to another for an exact fit
      Superwide (58mm) for comfort and traction control
      8mm Fast Kamber Mounting System (FKMS) allows camber angle adjustment for more control to keep a rider on the bike
      Available in three versions: F3, F5 and F6
      F3 footpegs feature SS setscrew teeth; easily adjustable and replaceable
      F5 footpegs feature SS press-pin teeth that are semi-replaceable (can be replaced up to three times); no adjustment necessary; just bolt up and ride
      F6 footpegs have the same great features as the F3 and F5 but have an improved cleat design to provide sure grip footing in any terrain
      Each system comes with reversible collars, springs, an 8mm FKMS system and teeth (F3 footpegs come with two different height setscrews, and F5 footpegs come with press-pin teeth installed)
    • By ThumperTalk
      Built-in ergonomics; adjustable grip, height and setup
      Electromagnetic-polished patented system
      Allow both standard and lowboy setup with reversible collar insert with each peg; collars may also be purchased separately to take footpegs from one make to another for an exact fit
      Superwide (58mm) for comfort and traction control
      8mm Fast Kamber Mounting System (FKMS) allows camber angle adjustment for more control to keep a rider on the bike
      Available in three versions: F3, F5 and F6
      F3 footpegs feature SS setscrew teeth; easily adjustable and replaceable
      F5 footpegs feature SS press-pin teeth that are semi-replaceable (can be replaced up to three times); no adjustment necessary; just bolt up and ride
      F6 footpegs have the same great features as the F3 and F5 but have an improved cleat design to provide sure grip footing in any terrain
      Each system comes with reversible collars, springs, an 8mm FKMS system and teeth (F3 footpegs come with two different height setscrews, and F5 footpegs come with press-pin teeth installed)
    • By ThumperTalk
      Cast from 17-4 stainless steel
      Provides a platform that is as much as 27% wider than stock (57mm vs. 45mm)
      Features IMS patented sprocket tooth design for unparalleled grip and mud relief
      Used by racers from Factory KTM, Team Green Off-Road and Honda Off-Road
    • By ThumperTalk
      Pro-series foot pegs are made of stainless steel
      More traction than stock. 50mm X 75mm
      Hard coated to prevent drooping
×