Sachs Cables

December 1, 2020

updated 2021-07

Sachs Cables

Sachs is both an engine name and a moped name.

 

1978 Sachs Westlake

 

 

Sachs mopeds are made in Germany by Hercules.
Cables for Sachs mopeds are in Hercules cables.

 

 

 

1978 Sachs 504

 

Sachs engines: Sachs 504 and 505 moped engines are made in Germany. They are on six USA moped brands or families (and many more worldwide). Different brands have different frames, handlebars, controls, and wheel brakes. Those things determine the cables.

 

 

Sachs cables: Cables for mopeds with Sachs engines are listed in these bike brands/families:

for Columbia mopeds with Sachs 505 engine, see Columbia cables.

for General   mopeds with Sachs 505 engine, see General cables.

for Hercules  mopeds with Sachs 504 or 505, see Hercules cables.

for KTM        mopeds with Sachs 504 engine, see KTM cables.

for Kynast    mopeds with Sachs 504 engine, see Kynast cables.

for Sparta     mopeds with Sachs 504 engine, see Sparta cables.

 

 

 


Choke Cables for Sachs 504 and 505 Engines

Sachs choke cables depend on what frame, what handlebar and what controls. The frame and handlebar matter only for the overall length.

Sachs-Hercules choke short 1-ended 170.80.08
’80-83 Sachs Prima G3, low bars with 505 foot brake
1982 Bombardier Eagle III with Sachs 505 foot brake

33.4+ = 31.8 + 1.6+ with pinch bolt
replacement black $12

Sachs-Hercules choke 1-ended 170.80.09
1970-77 Hercules M1, M2, P1 sheet frame, Sachs 504
1978-80 Sachs Westlake, Sundancer with Sachs 504
1973-77 Hercules M4, M5, P3 tube frame 505 foot brake

1978-80 Sachs Balboa, Suburban with 505 foot brake
1980-83 Sachs Seville, Prima with 505 foot brake
1982 Bombardier Eagle I, II with Sachs 505 foot brake

Sachs-Kynast choke     1-ended
1977-80 Kynast Flying Dutchman with Sachs 504
37.4+
= 35.8 + 1.6+ with pinch bolt

replacement black $12

Sachs-Sparta choke       1-ended 054011
1976-80 Foxi (Holland), Sparta Buddy with Sachs 504
Sachs-KTM choke xxx  1-ended 12.11.097
1977-80 Foxi (Austria) sheet frame with Sachs 504

Sachs-Columbia choke 1-ended 746-0292
1976-80 Columbia Commuter with Sachs 505
1977-82 Western Flyer, Imperial, Yard Man with 505
1987-95 KKM Mopet with Sachs 505 engine

39.6+
= 38.0 + 1.6+ with pinch bolt

replacement black $12

Sachs-Jui Li (early foot brake) 2-ended 2150-6284
1977-78 Jui Li Honey 50 with Sachs 505 foot brake
1977-78 Clinton 50-A, others with Sachs 505 foot brake

38.9″ = 36.4 + 2.5, for left start lever
replacement black $23

Sachs-General        2-ended 4150-6284
1978-85 General 5 Star, 5 Star ST with Sachs 505
1978-80 Jui Li, AMS, Sachs G4 Sachs 505 foot brake
1978-80 Grycner, Clinton with Sachs 505 foot brake
1981-85 Grycner, AMS, Jui Li, Clinton, Foxi  Sachs 505

37.9+ = 36.4 + 1.5+  right thumb lever
original black $20  replacement $20

Sachs-General       2-ended 415B-6284
USA made by Barnett, lined 

38.5″ = 1.4 + 37.1″  0.6″ longer
1980’s aftermarket $10

Sachs-General       2-ended 415S-6284
Taiwan made, Shorter for low bars

34.4″ = 1.5 + 32.9″  3.5″ shorter
1980’s aftermarket $10

 

 

 


Start Cables for Sachs 504 and 505 Engines

Sachs start  cables depend on what frame, what handlebar and what controls. All Sachs start (clutch-decomp) cables have to be single-ended because they must pass through a small 2.5 mm hole in the Sachs 504 or 505 engine case.

Sachs start (clutch) inner wire 1-ended WCS
47″ universal ’70-95 with Sachs 504 or 505 engine
replacement 1.5 mm
$21

Sachs-Hercules start short 1-ended 170.69.02
’80-83 Sachs Prima G3, low bars with 505 foot brake
1982
Bombardier Eagle III with Sachs 505 foot brake

34.4″ = 1.1+2.8+0.3+28.0+1.2+1.0
replacement black
$29

Sachs-Hercules start 1-ended 170.73.81
1970-77 Hercules M1, M2, P1 sheet frame, Sachs 504
1978-80 Sachs Westlake, Sundancer with Sachs 504
1973-77 Hercules M4, M5, P3 tube frame 505 foot brake
1978-80 Sachs Balboa, Suburban with 505 foot brake

1980-83 Sachs Seville, Prima with 505 foot brake
1982 Bombardier Eagle I, II with Sachs 505 foot brake
Sachs-Kynast start x 1-ended

1977-80 Kynast Flying Dutchman with Sachs 504
38.4″ = 1.1+2.8+0.3+32.0+1.2+1.0
replacement black
$29

Sachs-Sparta start 1-ended 054009
1976-80 Foxi GT, Buddy, Flying Dutchman, Sachs 504
Sachs-KTM start xxx 1-ended 12.11.195

1977-80 Foxi Deluxe sheet frame with Sachs 504

Sachs-Columbia start 1-ended 746-0293
1976-80 Columbia Commuter with Sachs 505
1977-82 Western Flyer, Imperial, Yard Man with 505
1987-95 KKM Mopet with Sachs 505 engine

40.9″
= 1.1+2.8+0.3+34.5+1.2+1.0
replacement black
$29

Sachs start cable long 1-ended 0291 021 000
universal long for 1975-85 with Sachs 504/1A, 505/1A 

46.6″ = 1.1+2.8+0.3+40.6+0.8+1.0
replacement black
$29 needs cutting or re-routing

Sachs-Jui Li (early foot brake) 1-ended 2150-6293 
1977-78 Jui Li Honey 50 with Sachs 505 foot brake
1977-78 Clinton 50-A, others with Sachs 505 foot brake

40.5″ = 1.1+2.8+0.3+34.5+0.8+1.0 with pinch bolt
replacement black $31 for General upper lever

Sachs-General        1-ended 4150-6293 
1978-85 General 5 Star, 5 Star ST with Sachs 505
1978-80 Jui Li, AMS, Sachs G4 Sachs 505 foot brake
1978-80 Grycner, Clinton with Sachs 505 foot brake
1981-85 Grycner, AMS, Jui Li, Clinton, Foxi  Sachs 505

40.3″ = 1.1+2.8+0.3+34.3+0.8+1.0 with pinch bolt
replacement black $31 for General lower lever

 

 

 


Throttle Cables for Sachs 504 and 505 engines

Sachs throttle cables depend on what frame, what handlebar and what controls. The frame and handlebar matter for the overall length. The frame also matters because low floorboards above the carburetor require a lower short-type throttle cable pipe, and that requires a throttle cable with a shorter exposed length. Some frames do not require a low cable pipe, but have it anyway.

Many bikes do not have their original throttle cable pipe (aka elbow, bendy) since the carburetor or top parts can be from other models or a remake. So to avoid guessing, the cable pipe length, short or long, must be identified visually, to get the correct throttle cable.

 

 

Hercules A x        1-ended 170.72.92
most ’70-76 Herc. M1, M2, P1 sheet frame with 504
most ’73-76 Moppet P504 with Sachs 504
most ’73-76 Herc. M4, M5, P3 tube frame 505 ft brk
most ’74-76 Moppet P505 with Sachs 505 foot brake

40.0+ = 35.5 + 4.5 + 1.3 with pinch bolt
170.72.92r       replacement black
$12
40.0 = 35.5 + 4.5 for short cable pipe

170.72.92Ar 2-ended replacement
$19

 

Hercules B x        1-ended 170.72.17
most ’77-83 Herc. M1, M2, P1 sheet frame with 504
most ’78-80 Sachs Westlake, Sundancer with 504
most ’77-83 Herc. M4, M5, P3 tube frame 505 ft brk
most ’78-80 Sachs Balboa, Suburban 505 foot brake
most ’80-83 Sachs Seville, Prima with 505 foot brake
most ’82 Bombardier Eagle I, II with 505 foot brake

40.0+ = 35.0 + 5.0 + 1.3 with pinch bolt
170.72.17r       replacement black
$12
40.0 = 35.0 + 5.0 for long cable pipe

170.72.17Br 2-ended replacement
$19

 

Hercules B short  1-ended 170.72.16 
’80-83 Sachs Prima G3, low bars with 505 foot brake
1982 Bombardier Eagle III with Sachs 505 foot brake

36.0+ = 31.0 + 5.0 + 1.3 with pinch bolt
170.72.16r       replacement black $12
36.0 = 31.0 + 5.0 for long cable pipe

170.72.16Br 2-ended replacement $19

 

Sparta  A xx 2-ended 054010
most ’76-78 Foxi, Buddy, Flying Dutchman, 504

Columbia A  2-ended 746-0291
most ’76-77 Columbia Commuter with Sachs 505
most ’76-77 Western Flyer models with 505
Kynast A xx 2-ended
most ’77-78 Flying Dutchman w/’77 covers, 504

41.0 = 36.5 + 4.5 for short cable pipe
746-0291Ar replacement black
$19

 

Gadabout  2-ended MS-4282 
with inline adjuster to fit either cable pipe

43.9 = 39.2 to 38.8 + 4.7 to 5.1
1980’s aftermarket black       $22

 

Sparta B xx  2-ended 054010B
most ’78-80 Foxi, Buddy, Flying Dutchman, 504

Columbia B  2-ended 746-0291B
most ‘
78-80 Columbia Commuter with Sachs 505
most ’77-82 Western Flyer, Imperial, Yard Man
most ’87-95 KKM Mopet with Sachs 505 engine
KTM B xxxx 2-ended 10.11.191
most ’77-80 KTM Foxi with Sachs 504
Kynast B xx 2-ended
most ’79-80 Flying Dutchman w/’79 covers, 504

41.0 = 36.0 + 5.0 for long cable pipe
746-0291Br replacement black
$19

 

General A     2-ended 1151-6296
most ’80-85 General 5 Star, 5 Star ST  Sachs 505
most ’80-83 General 5 Star ST with 505 foot brake
most ’80-85 AMS Sierra, Sachs G4  505 foot brake
most ’80-85 Foxi 47, AMS Tahoe with Sachs 505

38.2″ = 4.0+30.7+3.5″ for short cable pipe
1151-6296Ar replacement black $27

 

General B     2-ended 2150-6296
most ’78-80 General 5 Star ST with 505 foot brake
most ’77-80 Jui Li, Clinton 50-A with 505 foot brake
most ’78-80 Grycner, AMS Sierra 50  505 foot brake

38.2″ = 4.45 + 30.25 + 3.5″ for long cable pipe
original 
$32  2150-6296Br replacement $28

 

General B long 2-ended 215L-6296
aftermarket cable 2.5″ longer 

40.7″ = 4.45 + 32.75 + 3.5″ for long cable pipe
original 
$32  215L-6296Br replacement $28

 

 

 

Sachs-Magura Throttle Cables Raw Data: These data from actual original or vintage replacement cables were used to make specifications for replacement throttle cables. 

 carb   conduit exposed    
elbow   length  xx length xxcable  xxxx part
  xx    inch mm   inch mm x style  xxx number


short  33.5 852   4.53 115  Sparta xx 000-0000 most 1977-78 (Kynast) Flying Dutchman (early engine cover)
short  36.8 935   4.49 114  Sparta xx 746-0291 most 1976-78 (Columbia) Columbia (sheet-frame Sachs 505)
short  36.8 935   4.49 114  Sparta xx 000-0000 most 1976-78 (Sparta) Sparta Std., Deluxe, Foxi GT, GT Sport
short  37.0 940   4.49  113  Sparta xx 000-0000most 1977-78 (Sparta) Flying Dutchman Deluxe, Lucky
short  39.6 1007  4.61 117  Sp. repl.  000-0000 Sparta replacement for “Sachs-Magura with short elbow”
short  40.4 1027  4.80 122  Barnett x MP-0000 
Barnett replacement for “Sachs-Magura with short elbow”


either 38.9 988    113-125  Taiwan x MS-4282  Gadabout replacement with inline adjuster, for short or long elbow
either 38.8 986    121-131  Taiwan x MS-4282  (same)  apparently these are not all the same length


long   35.6 903   4.92 125  Puch xx   000-00000 most 1977-80 (KTM) Foxi Deluxe, Salzburg, Baron
long   35.6 903   4.92 125  Herc xx   000-00000 most 1976-80 (Hercules) Sachs models
long   33.5 851   4.92 125  Sparta x  000-00000 most 1979-80 (Kynast) Flying Dutchman (late engine cover)
long   36.8 935   4.96 126  Sparta x  746-0291B most 1978-80 (Columbia) Columbia (sheet and tube frame)
long   36.8 935   4.96 126  Sparta x  000-00000 most 1978-80 (Sparta) Foxi GT, GT Sport, Flying Dutchman
long   37.0 940   4.9  126   Sparta x  000-00000 most 1979-81 (Sparta) Sparta Buddy, Deluxe
long   36.7 932   5.08 129  Barnett  MP-0000 xx  Barnett replacement for “Sachs-Magura with long elbow”
long   36.4 925   5.23 133  Barnett  MP-0000 xx  (same)  apparently these are not all the same length

 

Long and Short Elbow (bendy): There is a 12mm (about 1/2″) difference between short and long elbow. For a short elbow the exposed length must be 114 to 121 mm. For a long elbow the exposed length must be 125 to 132 mm. The cable adjuster has an adjustment range of 7mm. So the 12mm of slack from a “long” cable used in a “short” elbow cannot be adjusted out.

To get around this, in the 1980’s one aftermarket Sachs throttle cable (Gadabout MS-4282) had an inline adjuster, with a wide adjustment range (13mm). This cable worked on either short or long elbows. 

 

Hercules P1 with short and long cable pipe

 

Hercules P1 models had both short and long cable pipes. Yet four Sachs engine parts catalogs (1975 Sachs 504, 1978 Sachs 504, 1977 Sachs 505, 1980 Sachs 505) list the same Sachs part number 0261-143-000 for the cable pipe. 

Like Columbia and Sparta, early models had short pipes and later models had long. The short pipe had a tighter bend that rubbed harder on the throttle cable. Some throttle cables would develop broken strands at the sharp bend. So the long cable pipe superseded the short one, on models that had enough space below the left floorboard. You can see on the red P1 photo the tops of the floorboard mounts are even with the top of the throttle cable pipe, but on the blue P1 the mounts are a little higher than the cable pipe. 

If you stand on the left floorboard, the mounts bend downward. Hercules designers first chose the short pipe because it would not be affected by standing on the floorboard, unlike the long cable pipe that would get broken from the rider’s weight on it. 

KTM long cable pipe

Sparta short and long cable pipes