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How To Rebuild Control Cables


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:

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 !!!

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