By David Porter, Customer and Technical Support at The Bonneville Shop
Table of Contents
Custom Motorcycle Cable
From time to time, we encounter an inquiry for a throttle or choke cable that is not available as pre-manufactured by our suppliers. There can be a number of reasons for non-standard fitment of cables, such as a change in handlebar height or width, the use of an aftermarket throttle twist-grip, or when a non-standard carburetor has been fitted in place of the original. There are also occasions where a rare motorcycle is being renovated and requires cables that haven’t been available for decades. The solution for this problem is to simply construct a custom motorcycle cable.
“There are also occasions where a rare motorcycle is being renovated and requires cables that haven’t been available for decades. The solution for this problem is to simply construct a custom-made cable.”
Choke and Throttle Cables
Choke and throttle cables are relatively easy to make in the home workshop. You will need some basic soldering skills, a soldering iron with 40 watt capability, some paste flux, and some 60/40 rosin-core solder in a thin gauge, around .050” thick. Technically, this type of solder is normally used for electrical purposes, but I have found it is ideal for throttle and choke cable construction, where only light loads are imposed.
Some may question the wisdom of using anything other than a “solder pot” for cable-making, but my method has served me well over the years, and the dainty little fittings on a throttle cable are well bonded when the correct methods are used in the soldering process. We have sourced some high-quality universal throttle cables from Barnett, which are 53” long and include several nipples and ferrules. We sell this cable under part number TBS-30002-08.
Front Brake custom motorcycle cable
“The 1968-only Triumph 650 front brake cable can also be used on many front brake applications, where absolute correctness is not a factor.”
Since we are on the topic of universal cables, here’s another option for the front brake cable, when the correct pre-manufactured cable is not available.
The 1968-only Triumph 650 front brake cable can also be used on many front brake applications, where absolute correctness is not a factor. We sell this cable under part number 60-0665. This cable is 58” long, which is plenty long for most applications where there is no factory cable available. The saddle that connects to the brake arm lever at the brake plate can be cut off, the housing shortened to the desired length, and can be coupled to the brake lever using the 60-0638 T universal brake cable end.
Once the correct length of inner wire is established, the cable end coupler can be fitted and tightened down, making a safe and effective front brake. The end of the cable inner wire can then be solder-tinned to prevent fraying. Since we don’t currently have a source for universal brake/clutch cables, this 60-0638 T cable can be an easy solution for fitting a custom motorcycle cable to your vintage BSA, Triumph, Matchless, Norton, or any other old motorcycle with a drum front brake.
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