Cheap and replaceable throttle cable solution

[Tant]

All

A couple of weeks ago I had the misfortune to have my throttle cable snap at the pedal end whilst quite a way from home.

I managed to drive it home by pulling the inner out of the outer, trailing it over the windscreen, and operating the accelerator by hand, which made for an interesting drive.

I tried to drill out the throttle end ferrule, so that I could use any old cable,and solder and crimp a new one in. Trouble was I couldn't drill it out as it was so small a hole.

I decided to make a new throttle end ferrule that would accept a replaceable cable.

I found a 10 mm stainless set screw with a long shank, and cut this section to the same overall length as the existing ferrule. I then drilled a hole the same as existing to slot over the throttle lever ball. I then drilled a hole in the end of the piece that the cable would fit into, and then drilled and tapped a hole through the "side" that would accept an allen headed grub screw to crimp down onto the cable.

I bought a piece of the right diameter bowden cable from B&Q (2 metres at 98p per metre) I slotted this into my new ferrule and nipped up the grub screw, then put the cable back through the existing outer sleeve, giving it a good silicone spray lube on the way. The retaining clip at the throttle end is a tight fit but seems to work fine and move freely.

I left the pedal end as it is for now, simply putting it into the slot, and fitting a ferrule at the end.In time, I'm going to make up a proper fitting that does not chafe the cable.

Now if the cable ever snaps again, it's a 2 quid length of cable from B&Q, or a bike brake cable inner to fix it. I now keep a length of cable in the car.

If anyone wants piccies I'll post some up.

Cheers
Ant

[steve j]

Tant said:

All

A couple of weeks ago I had the misfortune to have my throttle cable snap at the pedal end whilst quite a way from home.

I managed to drive it home by pulling the inner out of the outer, trailing it over the windscreen, and operating the accelerator by hand, which made for an interesting drive.

I tried to drill out the throttle end ferrule, so that I could use any old cable,and solder and crimp a new one in. Trouble was I couldn't drill it out as it was so small a hole.

I decided to make a new throttle end ferrule that would accept a replaceable cable.

I found a 10 mm stainless set screw with a long shank, and cut this section to the same overall length as the existing ferrule. I then drilled a hole the same as existing to slot over the throttle lever ball. I then drilled a hole in the end of the piece that the cable would fit into, and then drilled and tapped a hole through the "side" that would accept an allen headed grub screw to crimp down onto the cable.

I bought a piece of the right diameter bowden cable from B&Q (2 metres at 98p per metre) I slotted this into my new ferrule and nipped up the grub screw, then put the cable back through the existing outer sleeve, giving it a good silicone spray lube on the way. The retaining clip at the throttle end is a tight fit but seems to work fine and move freely.

I left the pedal end as it is for now, simply putting it into the slot, and fitting a ferrule at the end.In time, I'm going to make up a proper fitting that does not chafe the cable.

Now if the cable ever snaps again, it's a 2 quid length of cable from B&Q, or a bike brake cable inner to fix it. I now keep a length of cable in the car.

If anyone wants piccies I'll post some up.

Cheers
Ant

For cable terminations, I use these and of course, fully adjustable

[v8s4me]

More suggestions along the same lines here

http://www.pistonheads.com/gassing/topic.asp?h=0&a...