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How to Make a Motorcycle Cable

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How to Make a Motorcycle Cable
How to Make a Motorcycle Cable
John H Glimmerveen Licensed to About.com

Motorcycle cables have been used since motorcycles were first manufactured. These simple mechanical devices give the rider a means of controlling the throttle, clutch and brakes (where applicable) from the handlebars or foot pedal. For motorcycles in need of replacement cables, the good news is that most cables are available or can be manufactured to order. However, occasionally, a mechanic or classic owner may need to make a cable from a kit.

Making a motorcycle control cable is relatively easy and requires few tools. A number of companies supply kits or sell separately all of the individual items needed to make a cable.

Tools

The tools needed to make a cable include:

  • Gas fueled heat gun or heavy duty soldering iron
  • Good quality pliers
  • File
  • Solder
  • Soldering flux

Parts

In addition to the tools required, the mechanic will need the various component parts required to make up the cable. These include:

  • Inner cable (typically sized ‘1’ for throttle cables, ‘2’ or ‘3’ for clutch cables and ‘4’ or ‘5’ for heavy duty brakes—rear brake applications on sidecars, for example)
  • Outer cable
  • Cable ends
  • Cable end nipples
  • Adjusters
  • Rubber dust covers

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