How To Make Custom Motorcycle Cables - Throttle
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- čas přidán 20. 01. 2021
- In this video, I'll show you how I made a set of custom throttle cables for my Royal Enfield Interceptor 650. Obviously, you can do with this any motorcycle and it's a super handy skill to learn. This video focuses mainly on the process of prepping soldering your custom cables.
Thanks to the team at Venhill Engineering and Solder Connection for helping me in my research for this project.
Performance Mods:
**Disclaimer**
I have no affiliation with any of these companies or products. Please feel free to use these links as part of your research :)
Performance Mods:
- DNA Air Filter (stage II with open bracket)
www.tecbikeparts.com/product/...
- Booster Plug fuel system
www.tecbikeparts.com/product/...
- Scorpion Red Power pipes (please note this link is for the BLACK version, I can’t see the sliver anymore)
www.royalenfieldshop.co.uk/ho...
Hitchcock's Free Flowing Header Exhaust Pipes
accessories.hitchcocksmotorcy...
- YSS Top Line rear shocks
www.wemoto.com/bikes/royal_en...
- YSS fork upgrade kit
www.wemoto.com/bikes/royal_en...
- Motone Customs Up and Over Risers
www.motone.co.uk/triumph-bonn...
- Domino XM2 Throttle
www.ukracesupport.com/product...
- Brembo RCS15 / with TWM clutch
www.omniaracing.net/kit-coman...
- Brembo SA Sinter Pads Front
www.omniaracing.net/pastiglie...
Venhill Featherlight Clutch:
www.venhill.co.uk/r01-3-102.html
Other Mods:
- LSL SuperbikeBars
- Big Port Grips
- Highsider Montana Mirrors
- BAAK Side Pannels
- BAAK Tank Pads
- Motogadget MoBlaze LED Indicators (front and rear)
- BAAK Rear Indicator brackets
- BAAK front Indicator brackets
- Motone Customs Headlight Bracket
- Tec Bike Parts Rear Pegs
- Tec Bike Parts Chain Guard
- Tec Bike Parts Bash Plate
- Domino Switch Gear
Future mods in the pipeline include
- New tires (TBD)
- 4 Piston Calipers (TBD)
- LED headlight bulb - Auta a dopravní prostředky
Research this after having to pay $195 to motiopro for a custom cable for an xr100. I tried making a cable before using a torch and fried the cable. Since i ride crap bikes often the investment in a solder pot and the right materials seems wise long term. I have a bunch of bikes. Between throttles, clutches and multiple bikes, i need to master this. Thanks for making this approachable for me. Less $ and less downtime in the future.
Always make sure the barrel can turn freely when its put into the slot of the throttle because if it binds and bends the cable with every turn of the throttle it will cause the cable to fray and eventually break, learned this the hard way!😂🍻
Yes you got to make sure it can move. I use grease on the barrels for that reason.
Excellent explanation! Made a throttle cable last week and came out perfect, very strong connection of the brass barrel.
Awesome! I tried it today with copper flux and a random cable + a blowtorch and… after 4 tries… i gave up, the solder would never stick!… but after watching this, i see i have to do some more research
Glad the video helped. If you follow this method, you should have your cables done in no time.
Great video, can really tell you took the time to research and also ask around, thanks for solder explanation as i couldnt get a straight answer online, a lot of people said that high silver content was the way to go because lead was too soft, idk. Appreciate it man!
You are very welcome.
Great video! Thanks for posting 💪
Yea man proper pro class. This vid will be my go to for any future cable changes & upgrades
Thank you. Appreciate it 👍
Great result & clever to do a test piece 👌
Yes best to find fail on the bench rather than on the road. I couldn’t break them 👍
Well done great video, you have explained this all very well. I look forward to your videos.
Thanks George. Glad it helped.
Great technical info and a nice job done there WM.
I used a near identical process back in the day when I worked in a bike shop.......the number of clutch cables I repaired was countless. We used to call the fraying of the cable end a bird's nest rather than a bird's cage, but the technique was the same.
Thanks man! Good to know my technique is similar to the pros :)
Nice video!
Good to see you experimenting with the intro.
Thank you sir!
Nice vid J quality work there 👌 bit faffy for me tbf but you never know 🤷♂️ keep up the great content bud 👍🏻
It’s a bit of a faff, but kinda rewarding.
Great video, well done!
Subscribed
Thank you :)
Will definitely try this out on my custom built bike as the stock cable is too long and barely holding togetjer anyways 😛
I've swapped a Ninja front end onto a bmw airhead and have to make up a split cable. This is good help.
interesting your videos. Greetings from Colombia.
Thank you
Great video mate, I’ve purchased the stainless steel cables from venhill, still need to buy the flux and the solder. Do you know which solder for stainless cable? Thanks
Perfect! This is exactly the mod I have been looking for to do. Super appreciate you taking the time to create and share the content.
For the ends of the cable that meet the throttle housing - which hardware did you end up using? e.g. did you use the stock RE cable adjusters and ends or did you assemble it from the venhill kit?
Thank you! The adjusters came with the Domino Throttle, but you can pick these up from companies like Venhill.
04:10 'You want a tight fit, but if the hole's too tight, it's not gonna work.'
Yep, the statement applies to many things...
😂
Nice vid, I keep meaning to do mine as need longer (currently routed around back of forks). We did all cables on my wife’s Kawasaki this way using venhill kits. They are very good. I used a brass stop end and a candle for the solder pot. Worst part is the bird-caging without a tool I found.
Yes it's a bit of a pain. I found the side cutters do a decent job, just takes a while (and hurts when those little strands of steel stab your fingers.)
@@WildlifeMoto Exactly! Not quite as bad as the strands that fly off a wire grinder brush though, those are like being attacked by a legion of borrowers with spears!
I found holding the cable near the end with hemostats helps. Then just leave enough protruding to do the birdcaging. You don’t have to hold the hemostat by the finder loops. You can hold them near the pivot point. You have to do this part of the job with the cable barrel installed over the cable so there is not much cable sticking out. So it is awkward. That’s my approach anyway…
Kinga Tanajewska of "On Her Bike, Episode 90" had the front rim of her GS sealed to run the tire tubeless.
There's been no word on the result, but her opinion about it might be helpful for doing the same on the RE Interceptor.
Brilliant post thank you. What is that piece of music you use for your intro and outro (is there such a word?). Anyway, whatever it is always brings a smile to my face 👍🍻
Thank you. Here you go czcams.com/video/mkU9nC81Vsw/video.html
@@WildlifeMoto😀 that's brilliant thank you 👍.
I'll go down the custom route. Great instructions though👍
Cheers Mick
@@WildlifeMoto Have you uploaded a video showing the LED indicator installation? When j purchase my Interceptor I'll be looking into what to go for. All the best 👍
I do some occasional soldering but I’d never seen a soldering pot until I watched this video. An hour later I got an email from Revival Cycles pitching their new control cable dip soldering system. Apparently my home workshop is woefully incomplete, though I have to wonder how many times I’d use it. Until you post a video showing what else one can do with a soldering pot (lead fondu?) I may have to go without.
Haha, yes fairly limited use but it only cost £17. I’ll stash it away for next time me or a mate needs a new cable.
After making a smartass comment, I’ve come up with enough practical uses for a soldering pot (tinning wire for example) to justify the $25. I’ll begin by installing the Domino throttle and cable I bought on your recommendation.
Great video as usual, but how is that ever gonna save me money? :D Maybe after 35.000 cables done.
Nice. Now I know how they put the ends on all the bike cables I have bought over the years.
What kind of throttle cables is in the vide that you slide the wire in I have that same set on my bike but are dry rotted and can't find a replacement
Just had a go at this myself. One cable failed and it seems that, when the cable and nipple is inverted and dipped, it can allow the solder to run off the birdcage inside the brass fitting. Seems to work better if you tin the birdcage as normal, then gently nip the cable in a vice just below the brass end. Then heat the nipple with a small flame from a gas soldering iron. The solder then runs downwards in to the nipple and the birdcage. Seems much stronger that way.
I am no expert though... 🤣
So the barrels you used are the same size on both ends?
great vid. but you never talked about how to measure proper length? Since doing custom, my bike added tracker bars which is require longer throttle, and brake cable, might need clutch as well. I don't know how to get the proper length right the first time?? Any help much appreciated
Too long isn’t a major problem but too short obviously is. With that in mind, get a piece of steel rope and conduit that is too long, make it up and fit it at the butterfly end. Then route it up to your bars, ensuring you measure it with the controls steered over to the furthest point away. Finally mark up the unfinished end and cut it accordingly. Adding a couple of mill for safety is better than going to short.
That solder pot is a professional touch! How much did it cost you?
Thanks Dave. About £17 on Amazon.
did you say like the video? okay done
Thank you :)
I like that jingle! What is it?
From the CZcams Library - Called, Baroque Coffee House
@@WildlifeMoto Thank you!👍
Where can order the tools from
Most of us are going to home Depot and into the plumbing aisle.
What's there? The acetone?
Nice vid as usual! Can't help but think that unless you are going to make more than one set of cables, for one bike, all the paraphernalia and materials required to make them would outweigh the cost of buying the cables ready made from Venhill?
Suppose it depends how you look at it. Custom cables will run you around £60 (all in) and you could DIY a complete set for about £20 (that’s PTFE sleeves, wires, adjusters, barrels - everything). You’ll also have upfront costs like solder, flux, solvents, but I guess that’s all useful stuff to own for other things.
Nice, but you seem to have bought enough stuff to solder about 328 cables... What are you going to do with all this flux, solder and this melting pot? 😳
Haha. I’ll have to start the Wildlife Moto Custom Cable Company. It’s always handy stuff to have in the garage. I’m about to start building a drone so have several wires to tin, that’s just one use. I’m sure I’ll find more over the years. Thanks for watching.
6:47 I cringed a bit when I watched you file the end piece. Too much opportunity to get something out of round with a hard, flat file. I would have put it in the vice with the flats against the vice jaws. Then cut a bit of wet/dry sandpaper into a very thin strip - about 1/4 inch wide by about 6 inches long and sand it in a motion like you were shining your shoes. You will have to rotate it a couple of times but it will be come out much better IMHO. Otherwise, superb video.
Cheers for the tip David. 👍
uh, ya forgot to mention the $300 dollar solder pot.......
$300? I got it for £19 on Amazon.