There might be many reasons why someone would like to make their own throttle or clutch cables, and it doesn’t really matter what the reason is! The thing is, it is so simple, that you will wonder why on earth you looked it up online for guidance!
Anyway, In my case, I have swapped handlebars and they are wider than standard, and that’s on top of handlebar risers! Obviously my throttle cables became a bit on the short side!
Before making my own throttle cable I went to a few dealers with my standard cable to ask around if they had anything in stock, and there was one from a different bike with a cosmic price tag on it…
For a price comparison, the one from the dealer that ”might fit” would have been around 100 pounds, and the throttle cable KIT was only 34! Because my AJP PR7 uses only 1 cable for throttle – and the throttle cable kits normally come in pairs (push and pull) – ment i got a spare cable with it too! Bargain!
How to make your own length Throttle or Clutch cables
Well the process is simple. First of all need to determine what length is required. If starting from scratch best would be to route new cable in the right places and mark it where it needs shortening. In my case I knew that my standard cable was too short by only a few centimeters, and I already had it off the bike, so I simply laid it down on the table and placed my new cable’s outer shell right next to it. Marked it a few centimeters longer than a standard cable’s outer shell and using a saw for metal – trimmed it.
Trimming cable to size
Even simpler process – with standard and new cable on the table, pushed both cables as far as I could to one end, matched the length and trimmed it with snips. Since new cables came with fittings on one end already fitted – it made the job super easy too.
Fitting end fittings on the throttle / clutch cable.
The kit I ordered came with a few different sizes and types. Some more like a tube with thread that does not require soldering – just push in the cable, screw bolt provided and job done. I assume these can be used to test new cables as well as keeping them with tools to fix cables while out and about.
More permanent fittings are those that are soldered on, and that’s what I chose to use. And it also was as simple as.. Pushed the cable through the fitting, clapped in the vice to keep it in place, pushed cable threads to sides to spread them out a bit, smeared some soldering flux, heated up with a torch and added some soldering wire till it filled the hole.
It didn’t look very pretty at first as soldering wire leaked everywhere, but that was fixed with a few gentle strokes with a file.
Explore More!
A list of posts about Bike Maintenance and General Modifications that might be Interesting to know!
General Modifications:
- Throttle Tamer Mods (4 ways to tame your horse!)
- Projector headlight conversion from right side road traffic to left and vice versa.
- How to make your own Exhaust or how to modify an existing one.
- Power Commander (PCV) and Thoughts on it.
- Brake Snake / Pedal Anchor – why and how!
- Lighter Clutch Mods:
- How to make motorcycles Cable Clutch lighter! (Part 1/3)
- Cheap ways to make your motorcycles clutch lighter! (Part 2/3)
- How to make a Hydraulic clutch lighter on your motorcycle! (Part 3/3)
- How to make Custom Clutch or Throttle Cables – Easier than you thought!
- How to make clutch lever lighter (Yamaha XT660Z Tenere Specific)
- Rear Suspension and Drive-Train:
- How to extend the life of Cush-Drive rubbers.
- The dangers of motorcycle lowering links, Important things to know!
- How to swap rear shock spring with no special tools!
- The Best Motorcycle chain lube!
- How to set motorcycle chain slack when suspension is not standard?
- How To Remove Stubborn And Hard To Reach Chain Adjuster Bolt
- The List of Most Useless Adventure Motorcycle Mods And Bling!
- Dangers of the lowering kits (things to know before Lowering your Bike!
Bike Maintenance:
- How to pass MOT the first time – every time!
- How to Maintain your motorcycle Locks (works with all locks!)
- Best Suspension Bearing Grease!
- What grease to use on your motorcycle?
- How to shorten Life of your wheel bearings! (Or what not to do to them!)
- Why should you grease your bolts! (And not only Bearings!)
- What is the best Chain Lube for your motorcycle?
- How to buy used Motorcycle – Free Guide.
Explore more!
- Important things to know about your AJP PR7 – Torque Vales / Bearing / Seal Sizes / Manuals and Stuff.
- How I stored All my Trail Tools and Spares on my AJP PR7.
- AJP PR7 Tool Sizes.
- Cheap ways to make your motorcycles clutch lighter! (Part 2/3).
- How to make a Hydraulic clutch lighter on your motorcycle! (Part 3/3).
- Is it possible to fit the New Athena ECU on the old AJP PR7?
All AJP PR7 MODS:
- Relocated Voltage Regulator Rectifier.
- Radiator Guards / cages.
- Radiator Mud Guard Mod.
- Crash Bars.
- Air filter box and Filter cover Modification.
- Crankcase Breather Modification.
- GUGLAtech Fuel strainer pre-filter mod.
- GUGLAtech pre-filter mod v.2
- Headlight Converted From EU to UK.
- Tablet ON/OFF Switch.
- EnduroParts +45mm handlebar risers.
- EnduroHog Engine side covers.
- Quantum – Upgraded Fuel Pump.
- OEM Fuel Pump Mod – No More O-rings!
- Quantum Fuel Pressure Regulator Replacement.
- Fuel pump relay mod.
- Oberon Clutch Slave.
- Dash Voltmeter.
- Rear Luggage Rack.
- Oxford Heated Grips.
- Extended Clutch and Throttle Lines.
- Extended Front brake Line.
- Seperate Wiring loom for chargers and stuff.
- 3Dmoto Rised Fuel Filler cap.
- 3Dmoto Stainless Steel Rear Wheel Spacers.
- 3Dmoto Stainless Steel Front Wheel Spacers.
- Improoved Fuel Tank Breather.
- Exhaust Wrapped.
- Brackets to strap Soft Lugage.
- Auto Headlight mod.
- Silly Idle control screw mod (or Maybe not!)
- Coolant bottle mod – no more spills!
- Bent exhaust solutions
OR
