Magura Controls

July 14, 2014

updated 2020-05

Contents:  1. 70’s – 80’s Magura Parts
Contents:  2. Magura Moped Controls
Contents:  3. Service Information

 

Magura 1975 logo

 

German flag

 

 

 

 

Magura was founded in 1893 by inventor Gustav Magenwirth as a manufacturer of gasoline motors, hydraulic press pumps and water pressure devices. Since 1923 in Bad Urach, Germany, they have produced handlebars and handlebar controls for mopeds and motorcycles. They are an industry leader, and still produce handlebar controls for all major makes. Since the 1970s, the company has also made many products for the bicycle industry. The name Magura is from Magenwirth and Urach. The logo is from a rotary rack developed in 1930.

Magura levers late and early

Left 80’s, right 70’s

Wrap-around and Slide-type: There are two main types, wrap around where the throttle cable wire wraps around and attaches to the twist tube, and slide type where the throttle cable attaches to a block that slides in a spiral slot in the twist tube.

70’s and 80’s: It is a subtle difference, but side by side you can see there are two different folded aluminum original Magura levers. The 1980’s “late” right lever, on the left, is longer and straighter than the 1970’s “early” left lever, on the right. When they are not side by side, it is really hard to notice. 

 

 


1970’s -80’s Magura Parts

Price colors: dark green is good-used, green is new, N/A is not available
Abbreviations:  TBCH is threaded brake cable hole,  TBLSH is threaded brake light switch hole, AC is auto choke

Right assemblies with item #s and links to photos
R1    N/A    2b 3x 4 6 7 9 10s 13a 15a 70’s silver use R3
R1b  N/A    2b 3x 4 6 7 9 10s 13b 15a 70’s black use R3b
R1n $45.0 2b 0x 0 6 7 9 10s 13n nox 70’s silver, no twist tube, no BLSTH
R2   $80.0 2b 3a 4 6 7 9 10s 13c nox 70’s silver, AC (74-79 Tomos)
R2b  N/A    2b 3a 4 6 7 9 10s 13d nox 70’s black, AC (78-79 Tomos) use R4R
R3   $73.0 2c 0x 4 6 7 9 10s 13e no   80’s silver
R3   $45.0 2c 0x 0 6 7 9 10s 13e no   80’s silver, minus twist tube
R3b $73.0 2c 0x 4 6 7 9 10s 13f15z  80’s black
R3b $45.0 2c 0x 0 6 7 9 10s 13fno   80’s black, minus twist tube
R3r$65.0 2r0x 4 6 7 9 10s 13r  no   all black Agis replica
R4    N/A    2c 3a 4 6 7 9 10s 13g nox 80’s silver, AC (80-85 Tomos) use R4R
R4b  N/A    2c 3a 4 6 7 9 10s 13h nox 80’s black, AC (84-85 Tomos) use R4R
R4r$75.0 2r3a 4 6 7 9 10s 13snox all black Agis replica, AC auto-choke
R5p  N/A    2b 3x 4 6 7 9 10a 13p 15a 70’s silver TBCH (Peugeot)
R5q  N/A    2c 3x 4 6 7 9 10a 13q 15a 80’s silver TBCH (Peugeot)
R6b$55.0 2b 0 4b 6 7 9 10s 13u nox 70’s black open-type wrap-around
R7    $65.0 2c 22-25 6 7 9 10s 21x no  80’s black slide-type (Puch Maxi Luxe)
R7c  N/A    2e 22-25 6 7 9 10s 21x no  80s blk slide-type cast lever (Magnum)

Left assemblies with item #s and links to photos
L1   $42.0 1b 6 7 8 10s 12a 14 16 17 18 70’s silver
L1b $45.0 1b 6 7 8 10s 12b 14 16 17 18 70’s black
L2   $38.0 1b 6 7 8 10s 12c 14 00 00 00 70’s silver brake only (74-79 Tomos)
L2b $40.0 1b 6 7 8 10s 12d no 00 00 00 70’s black brake only (78-79 Tomos)
L3   $47.0 1c 6 7 8 10s 12e 14 16 17 18 80’s silver
L3b $45.0 1c 6 7 8 10s 12f 14 16 17 18 80’s black
L4   $39.0 1b 6 7 8 10s 12g 14 00 00 00 80’s silv brake only (80-85 Tomos)
L4b $39.0 1b 6 7 8 10s 12h 14 00 00 00 80’s blk brake only (84-85 Tomos)
L4p $32.0 1p 6 7 8 10s 12g 14 00 00 00 80’s park-brake only (Tomos trike)
L4r$29.0 1r  6 7 8 10s 12r  no 00 00 00 all black Agis replica TBCH only
L5p  N/A    1b 6 7 8 10a 12p 14 16 17 18 70’s silver TBCH (76-79 Peugeot)
L5q  N/A    1c 6 7 8 10a 12q 14 16 17 18 80’s silver TBCH (80-83 Peugeot)
L6    N/A    1c 6 7 8 10s 12fno 16 17 18 80’s black (78-84 Puch Maxi Luxe)
L6e $40.0 1e  6 7 8 10s 12b no 16 17 18 70’s black (78-79 Puch Magnum)
L6c $48.0 1e  6 7 8 10s 12fno 16 17 18 80’s black (80-84 Puch Magnum)
L8   $24.0 no 0 0 0 10s 12z 14 16 17 18 start only (Sachs 505 foot brake)

All of these levers interchange and are 12mm wide at the pivot.
Original levers have a 6 mm top hole and a 5 mm bottom hole.
Some bottoms are the same as tops, others have a cable slot.
Flipping (using a right lever on the left side or visa versa):
Right and left interchange when flipped (bottom becomes top).
If the lever is flipped the pivot bolt must also be flipped, unless
the 5 hole is drilled to 6 and the 6/5 pivot bolt changed to 6/6.

1 Left levers:
1a  $38.0 L lever folded alum. Magura no ball
1ar
$12.0 L lever folded steel  generic no ball
1ar $00.0 needs 6/6 pivot bolt to work well

1b   N/A    L lever folded alum. Magura short
1bs $20.0 substitute: lever 2b upside down
1bs $00.0 for bolt 6a installed upside down
1bd $28.0 substitute: 2bd upside down + 6e
1bd $00.0 for bolt 6a installed right side up

1c   $29.0 L lever folded alum. Magura long
1cr $24.0 L lever folded alum. generic long
1d   N/A    L lever folded alum. Magura black
1dr  N/A    L lever folded alum. generic black

1e  $36.0 L lever cast aluminum Magura
1er  N/A    L lever cast aluminum TCCD
1g  $25.0 L lever folded aluminum Agis black
1gd $14.0 2g drilled to 6/6 (both holes 6mm)
1gd $00.0 needs 6/6 pivot bolt to work well

1p  $26.0 L lever folded al. with parking brake
1p   $00.0 mostly for three-wheel mopeds

2 Right levers:
2a  $34.0 R lever folded alum. Magura no ball
2ar $12.0 R lever folded steel  generic no ball

2b  $20.0 R lever folded alum. Magura short
2bu $15.0 2b good used or straightened
2bd $22.0 2b drilled to both holes 6 mm
2c   $20.0 R lever folded alum. Magura long
2cr  N/A    R lever folded alum. generic long
2d  $32.0 R lever folded alum. Magura black
2dr  N/A    R lever folded alum. generic black

2e  $25.0 R lever cast aluminum Magura
2er  N/A    R lever cast aluminum TCCD
2g   $12.0 R lever folded aluminum Agis black
2gd $14.0 2g drilled to 6/6 (both holes 6mm)
2gd $00.0 needs 6/6 pivot bolt to work well

S Lever sets R and L: with item #s
Sg   $26.0 lever set black 2gd 1gd 6b 6b 7d 7d
Sgb $30.0 lever set black 2gd 1gd 6c 6c 7c 7c
Sb   $44.0 lever set short  2b  1bd re-use bolts
Sbb $38.0 lever set short  2b   2b  flip left bolt

3 Lower right levers:
3x $11.0 right thumb lever original, locks-in off bar
3a $29.0 choke trigger and spring for early Tomos A3
3b $8.00 right thumb lever replacement, locks-in off bar

4 Twist tubes: with grip length
 $23.0 twist tube 100 mm original white (cable loads from front)
4b $19.0 twist tube 100 mm original black (cable loads from front)
4c 
  N/A   twist tube 115 mm original black (cable loads from front)
4g $37.0 twist tube 100 mm #4 with ribbed grip #15 original

4r$15.0 twist tube 100 mm Agis black (cable loads from back)

For best performance, this should fit and be smooth
where the lever rubs at.

5 to 11 Hardware
5    $1.50     friction plate to make throttle stick (leave off)
6a  $2-$1   pivot bolt 6/5 orig slot dome M5 x 20 smooth ∅6  x  8.5
6b  $1.20   pivot bolt 6/6  allen short    M6 x 20 smooth ∅6  x  2.0
6c  $3.00   pivot bolt 6/6  black phillips M5 x 25 smooth ∅6 x 11.5
6d  $6.00   pivot bolt 6/6  6a with 6e    M5 x 20 smooth ∅6 x 11.5
6e  $4.50   adapter sleeve changes 6a to 6d  ∅5 smooth ∅6  x  3.0
6f   $0.70   pivot bolt 6/6  allen head     M6 x 20 not smooth
6g  $0.80   pivot bolt 6/6  phillips head M6 x 20 not smooth
7a  $0.70   pivot nut M5 plastic-lock original light gray
7b  $0.70   pivot nut M5 plastic-lock original black
7c  $0.55   pivot nut M5 metal nylock
7d  $0.65   pivot nut M6 metal nylock
7e  $1.00   pivot nut M5 metal nylock black
8    $3.00   left return spring
8b  $2.00   return spring R or L (not for solid cast levers)
  $2.00   right return spring
10s $2.00   clamp screw M6x16 slot dome head
10a $0.70   clamp screw M6x16 allen head (Peugeot)
11   $4.00   socket bolt  aka cable anchor/adapter

12 Left housings: with brake switch hole, unless noted
12a $15.0 left housing 70’s silver
12b $15.0 left housing 70’s black
12c $15.0 left housing 70’s silver no start lever (74-79 Tomos)
12d $17.0 left housing 70’s black no start lever (78-79 Tomos)
12e $22.0 left housing 80’s silver with mirror hole
12f$22.0 left housing 80’s black with mirror hole

12g $15.0 left housing 80’s silver no start lever (80-84 Tomos)
12h $15.0 left housing 80’s black no start lever (84-85 Tomos)
12n $10.0 left housing 70’s silver no brake light switch hole
12p $30.0 left housing 70’s silver with TBCH (76-79 Peugeot)
12q  N/A    left housing 80’s silver with TBCH (80-83 Peugeot)

1974-85 Tomos auto-choke 
Thumb button activates choke by
allowing grip to twist in reverse.

13, 21 Right housings: with brake switch hole, unless noted
13a $30.0 right housing 70’s silver
13b  N/A    right housing 70’s black
13c $37.0 right housing 70’s silver with choke slot (74-79 Tomos)
13d  N/A    right housing 70’s black with choke slot (78-79 Tomos)
13e $27.0 right housing 80’s silver
13f$33.0 right housing 80’s black
13g $37.0 right housing 80’s silver with choke slot (80-85 Tomos)
13h $35.0 right housing 80’s black with choke slot (84-85 Tomos)
13n $25.0 right housing 70’s silver no TBLSH (Euro version)
13p $37.0 right housing 70’s silver with TBCH (76-79 Peugeot)
13q $39.0 right housing 80’s silver with TBCH (80-83 Peugeot)
21   $20.0 right housing black screw-slide-type  (some 78-83 Puch)
21b $29.0 right housing black slotted-slide-type (some 84-86 Puch)

14, 15 Grips:
14   $3.00 left  grip  100 mm black ribbed original
14b $8.00 left  grip  100 mm black waffle original
14c $6.00 left  grip  115 mm black block original
15   $18.0 right grip 100 mm black ribbed original
15b $28.0 right grip 100 mm black waffle original
15c $9.00 right grip 115 mm black block original
20   $11.0 grip set 105 mm #14, 15 ribbed replica
20c $12.0 grip set 115 mm 14c, 15c block original

16 Left lower levers:
16  $14.0 start lever new black plastic with screw
16b $32.0 start lever aluminum long w/screw (Puch 2-spd)
17  $1.50 pinch screw 4mm
18  $3.00 pivot pin
18b $1.00 pivot pin substitute screw M4x20

19  $10.0 clamp-on metal lever substitute for trigger #3
22   N/A    pin that holds twist tube
23  $3.00 screw for sliding block (some 78-83 Puch)
24  $26.0 sliding block screw type (some 78-83 Puch)
24b  N/A    sliding block late no screw (all 84-86 Puch)
25  $28.0 twist tube Puch slide-type plastic

 

 

Magura Moped Controls 


Sears Allstate throttle control

Sears Allstate right control

Sears Allstate left control

Sears Allstate left control

Magura “Open Wrap Around” silver controls are used on 1950’s and 1960’s Puch, Tomos, Sears Allstate, and many others. Some are cast aluminum levers, and some are folded sheet aluminum.

Most of these did not have threaded holes for brake light switches.

Ball-end levers began in the 1970’s, for safety.  

 

 


Magura late open wrap around right control

Magura late open wrap around right control

Magura black left

Left black housing,
both start cable and
brake cable holes are
plain with bottoms

Magura “Open Wrap Around” black controls were on 1980’s Euro models, but not on US models.

Like the other Magura wrap around throttle controls, the twist tube has a groove that locks onto a tab in the housing. The two are locked together first, then slid onto the handlebar. Once on the handlebar they cannot become separated.

These have a plain hole with bottom, for the brake cable. Most do not have a hole for the a brake light switch.

 

 

 


Peugeot or Not Peugeot: There are two ways to stop the brake cables. The Peugeot way is to have 6mm threaded bottomless holes in the housings with 6mm adjusters stopping the cables. The non-Peugeot way is to have the housings stop the cables (or the inline Magura-type adjuster) with a slotted recess (hole with a bottom) instead of threads. You can convert to Peugeot style by drilling and tapping to M6-1.0 thread. But there is almost no adjustment range (because most of the hole is already too big, 7mm).

Magura wrap around throttle illustration

Magura right control
(with choke trigger)
plain with bottom
for no adjuster or
Magura type adjuster

Magura wrap around throttle threaded brake hole

Magura right control
(with choke trigger)
threaded M6-1.0 for
brake cable adjuster

Magura left housing versions

Brake cable hole versions:
L, threaded bottomless hole (Peugeot)
R, plain hole with bottom (non-Peugeot)

 

 

 

 

 

 

 

 

 

 

 


Magura wrap around silver housing

Magura right housing
with brake switch hole,
brake cable hole is plain with bottom

Magura left control Tomos 213706

Magura left control for
Tomos (no start lever),
no brake switch hole,
brake cable hole is
plain with bottom

Magura “Wrap Around” silver controls are used on 1970’s Batavus, Colombia, Flandria, Foxi, Flying Dutchman, Hercules, JC Penney, Kreidler, KTM, Kynast, Murray, Odyssey, Puch, Sachs, Sears, Sparta, 74-85 Tomos, and others. These US models all had threaded holes for brake light switches. Most Euro and Canada models did not have brake light switch holes. 

The brake cable holes on both sides have two versions, M6 threaded bottomless (Peugeot style), or 7mm plain hole with bottom (non-Peugeot style). 

These controls on US models all had ball-end levers except for Sears Free Spirit.

 

 


Magura-clone right control

Magura-clone right control

Magura-clone left control

Magura-clone left control
no start lever (Tomos type)

Magura-clone “Wrap Around” black controls are used on 1979-85 Tomos Silver Bullet. They are made in Yugoslavia to be Magura-compatible. 

Black Magura Levers

Magura-clone levers

The brake cable holes are 7mm plain with bottoms. 

 

 

 

 


Magura late silver left control

Magura late left control

Magura late silver right control

Magura late right control
shown with no grip

 

Magura “Late Wrap Around” silver controls are used on 1980’s Colombia, Hercules, Murray, Puch, Sachs, 79-83 Trac, and others. The housings are thicker and less rounded. The left has a mirror hole. US models had threaded holes for brake light switches. But most Euro and Canada models did not have brake light switch holes. In these photos you cannot tell if there are brake switch holes or not.

The brake cable holes on both sides have two versions, M6 threaded bottomless (Peugeot style), or 7mm plain hole with bottom (non-Peugeot style). 

 

 


Magura late black right control

Magura late right control

Magura late black left control

Magura late left control

Magura late black Tomos right control

Magura late right control
Tomos A3 choke button

Magura “Late Wrap Around” black controls are used on 80-83 Puch Maxi, 80-85 Sachs (Hercules) and others.

The brake cable holes are 7mm plain with bottoms. 

 

 

 

 


Puch-Magura “Sliding Block” black, used on 78-86 Puch deluxe models. 

Most of these are the early, common kind with a screw on the slider holding holding the cable wire. The cable wire itself has no upper end piece. It  takes a “universal” or “single ended” throttle cable.

Some of these are the late, uncommon kind with no screw on the slider. Instead the cable wire has an upper end piece 3mm “inline barrel” soldered onto it. The cable is specific to that set-up, and is “double ended”.

The brake cable holes are 7mm plain with bottoms.

Puch Magura sliding block controls

Puch Magura sliding block black controls

Magura slide throttle late (no screw on slider) and early (screw on slide)

Left: Slider with a pinch screw for Puch 1978-83
models Maxi Luxe, Newport, Sport, Magnum
(takes a single-ended throttle cable)
Right: Slider with no pinch bolt for Puch 1984-86
all models. Housing has a slot for cable.
(takes a double-ended throttle cable)

xx

 

 

 

 

 

 

 

 

 

 

 

 


Service Information

The tongue and groove lock together, but only when they are off the handlebar.

Magura Wrap-Around Throttle

As mentioned above, the pieces snap together, but only when removed from the handlebar.

Twist tube: The throttle housing has a tongue that goes into a groove in the twist tube. The two pieces are first locked together while off the handlebar, and then slid on as a unit. Then the twist tube is kept from moving sideways. 

Thumb trigger: Not all mopeds have this, but all the wrap-around housings have a provision for it. This is also called a choke lever or a decomp lever. The trigger has half-circle-shaped posts that slide into slots in the throttle housing, but only when off the handlebar, and in the “squeezed past max” position. Once on, the handlebar prevents it from detaching.

Tomos A3 auto choke thumb button: This button, when pushed in, lets the throttle cable go all the way slack for cold starting.  When it is not pushed in, it allows the cable to stay a little taut for normal idling. Idle speed is adjusted by the tightness of the throttle cable, at the handlebar by the Magura type cable adjuster.

Installing a throttle cable on a Magura wrap around type throttle

Installing a throttle cable on a Magura wrap around throttle

 

Installing a throttle cable: With an original Magura twist tube, the cable installs from the outer side, just behind the grip. Turn the grip forward to the closed position. Locate where the cable end is. Peel the flange of the grip there back with your thumb, and hold it there. With the other hand, place the sideways barrel end of the throttle cable into the cavity. Lay the wire over the ridge, and wrap it around the curved guide. When pulled taut it should fall into it’s groove. The throttle should pull the wire and move free.

With a Magura-clone twist tube, the cable installs from the inner side. So the twist tube has to be removed. That means the whole throttle has to be removed from the handlebar. But the cable is more protected.  

 

How to install the throttle cable:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Restoring a worn groove

Restoring a worn groove

 

Restoring a damaged groove: The curved cable guide groove can become worn in the middle. It can be so bad that the throttle feels like a hack saw, the way it makes a ripping sound, has a rough feel, and sticks sometimes. It cuts through cables. The cause of the worn groove is lack of lubrication. Moped cables and controls need oil occasionally.

The remedy is to re-cut the bottom of the curved guide. The best tool is a masonry hack saw blade. It has the exact width and round shape. The linear saw is moved in a curved motion. The bottom of the channel is visually checked every few strokes, to see what areas need more cutting.

 

Magura throttle brake and choke cable exposed lengths

Tri-Flow lubricant

 

Lubrication: Lube the cables and controls with a drip oil, like 3-in-1 or Tri Flow or any high tech lubricant. Tri Flow is thin so it penetrates in and clings to metal, like WD40. But after awhile when most of the liquid drys up, it leaves behind microscopic Teflon particles embedded in the metal surface.   

Making custom cables: Here are the distances of the exposed cable wires, for Magura wrap-around type moped controls.