How To Shorten or Repair Throttle Cable, Brake or Clutch Cables with Solder - Motorcycle | Part 18
In this episode, I adjust the length of the throttle cable for my Honda CB750 project motorcycle. I am building this bike to be a road-going runner, not a full restoration. The bike is a bitsa, and came with a different set of carbs than the ones now fitted.
Here's what I used in this video:
Brass nipple: https://ebay.us/nQXvYS
Flux: https://ebay.us/gcUFD3
Blow torch: https://ebay.us/sYV6SY
This seems to be a frequent problem that I run into, not just on this bike but with the Triumphs I have worked on. Maybe I am just expecting too much from cheap throttle cables, but when you have changed the twist grip and the carbs it is impossible to know if the original spec cable will fit anyway!
Luckily it has mostly been a case of trimming the outer cable so that the inner cable pokes out a little bit more. For this one, though I need to shorten the inner cable, it was about 2 inches too long.
I used a brass solder on the nipple. Make sure you get the right size, not all nipples are equal :) In this case, it was 6mm outside diameter.
It is possible to make a former and cast your own solder nipples on the end of the inner cable, but I haven’t tried that, yet! You can also get ones with a grub screw to secure them, these tend to be for emergency use though.
The brass nipples work just fine, but you do have to remember to use flux. The flux makes the solder flow better and give a better join between the nipple and the cable.
For more helpful how-to guides and restoration project logs, visit our blog: https://www.spannerrash.com/
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