Cables

November 29, 2020

updated 2020-12

Contents:
1. Service Info  2. Generic Cables  3. Inner Wires

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1. Service Info

Welcome. This cable section is for control cables, that slide back and forth, not speedometer cables, that rotate. For speedometer cables, see Parts/Frame/Speedometer

Single or Double Ended: Some control cable inner wires have two ends, and some have only one. The “end” is a round piece if metal, usually soldered onto the braided steel wire. When a cable inner wire has only one end, it can be removed from the conduit (or sleeve or housing). When a cable inner wire has a ball of lead at both ends, then it is permanently trapped and cannot be removed without cutting one end off.

Tri-Flow lubricant

Tri-Flow

Oil can

Squeeze type oil can

3-in-one oil

3-in-1 oil

Lubing Cables: Old cables become sticky from deteriorated oil and corrosion. A few drops of fresh thin oil is often all the cable needs to work good again, after a long period of sitting. Apply a few drops of oil or synthetic lubricant (preferably Tri Flow) onto the upper exposed inner wire so that it runs downhill into the cable. The bike is leaned over so that cable entrance is going down. The oil takes a few minutes to flow down the wire. Straighten out any kinks in the cable. Also lube the throttle, especially sliding block kinds, and the levers, where the lever pivots, and where the cable pivots.

 

Cable cutter

Cable cutter

Cable end wires bent into an umbrella before soldering

End wires bent
into an umbrella
before soldering

Soldering iron

Soldering iron

Cutting cables: The preferred tool is called a diagonal cutting pliers. It must be fairly new and sharp to cut braided steel cable inner wires and coiled steel cable outer conduits. Most of the inexpensive kinds do not stay sharp long. 

Configuring cables: A single ended “universal” cable is configured, or made into, a double ended “specific” cable. Any cutting of the sleeve, adding stop pieces, adapters or adjusters is done first. Then the cable is installed on the bike. Lastly, the top end piece is installed in the correct location on the wire. The wire strands are bent into an umbrella, and soldered. This is often necessary when ready-made cables are not available.

 

 


2. Generic Cables

C1 front brake (most)

Rear Brake Cable

C2 rear brake (most)

C3 throttle cable (most)

C4 clutch (some)

C4 start/clutch (some)

 

 

 

 

 

 

 

 

 

FRONT BRAKE
sleeve x wire
upper end
lower end
REAR BRAKE
sleeve x wire
upper end
lower end
THROTTLE
sleeve x wire
upper end
lower end
START CABLE
sleeve x wire
upper end
lower end
CHOKE CABLE
sleeve x wire
upper end
lower end
Generic Cables
5mm black lined sleeve
6mm chrome end caps
39 x 48" Ø1.5
6mm pear
no end
C1 409600 $10
60 x 65" Ø1.5
6mm pear
no end
C2 14111 $10
37 x 47" Ø1.2
no end
3x5 inline
C3 409500 $12
43 x 51" Ø1.5
6mm pear
no end
C4 409800 $10
same as
throttle

 

 


3. Cable Inner Wires

WR1 brake wire

WT1 throt. wire

Cable Ends on Replacement Cables

Cable Ends on Replacement Cables

 

 

 

 

 

 

 

FRONT BRAKE
single ended
inner wire
REAR BRAKE
single ended
inner wire
THROTTLE
single ended
inner wire
CLUTCH
(START)

single ended
inner wire
DECOMP
(START)

single ended
inner wire
CHOKE
single ended
inner wire
Moped Inner Wires
(vintage European)
WF1 48" Ø1.5
6mm pear end
500000 $5
WR1 69" Ø1.5
6mm pear end
500100 $5
WT1 47" Ø1.2
3x5 inline end
409900 $5
WC1 67" Ø1.6
6mm pear end
14238 $5
WD1 40" Ø1.2
5x7 barrel end
decomp $8
same as
throttle
Long Wires
for high or wide bars
or modified frames
WFL 73" Ø1.5
6mm pear end
1456 $5
WRL 105" Ø1.5
6mm pear end
1410 $8
WTL 79" Ø1.2
3x5 inline end
1457a $8
same as
rear brake
same as
throttle
Thick Inner Wires WF2 49" Ø2.0
6mm pear end
thicker $8
WR2 65" Ø2.0
6mm pear end
thicker $12
none WC2 51" Ø2.0
6mm pear end
Vespa $5
none same as
throttle
Barrel Inner Wires WF8 49" Ø2.0
8x8 barrel end
thicker $10
WR8 65" Ø2.0
8x8 barrel end
thicker $12
WTP 47" Ø1.2
5x7 barrel end
Peugeot $8
WCS 48" Ø1.3
Ø5/6 barrel end
Sachs $17
Bicycle Inner Wires WF7 48" Ø1.5
7x7 barrel end
1456b $5
WR7 73" Ø1.5
7x7 barrel end
1456a $5
WTG 79" Ø1.3
4x5 inline end
1457 $5