Just today I broke my FXR150 throttle cable and had to make a quick but permanent fix for the race tomorrow. You will need:
- a new inner throttle cable - the same thickness as old cable
- the old sleeve the cable ran through
- a bolt - size varies depending on the size of the nipple on the original cable
- a drill with tiny drill bits
- soldering iron and solder
- a vice will make this very easy, without it I hope you have grizzly bear hands
This is how I did it:
Ok. The new inner throttle cable may come with one or two nipples, you will most likely have to shorten the cable therefore you will need to make a new nipple (well not necessarily, you could use the old one but this is how I did it). If the cable comes with no nipples then you will be making 2 nipples.
Find a drill bit that matches the same thickness of the cable. Put the bolt that is the right thickness for the nipple required in a vice and drill a hole straight through the bolt. You then need to get a drill bit that is much larger, almost the same thickness as the bolt but still a little smaller and drill a hole 1/3 the way through the bolt at the original pilot hole. Cut the bolt so the nipple has the hole in the dead centre of it and is the right length.
Take the new cable and assemble it up at the throttle handgrip if it already has a nipple on it. *Otherwise skip to how to attach the new nipple*. Feed the cable through the sleeve and get the cable in the right position as if to attach it. Mark out on the cable where the new nipple will be attached and cut the cable a fraction longer (5mm). Now the fun part.
*How to attach the new nipple:
Feed the cable through the smaller hole from the bottom end up to the end where the larger hole was drilled. Bur the end of the cable at roughly 3 - 5mm, trying to be accurate with keeping the right length of the cable. The cable should now not go back through the small hole but should sit nicely in the larger hole you have drilled. Take out the soldering iron and the solder and fill the hole in. DONE!! You might need a hand file to smoothen things so it all fits back together properly.
Attach it up, adjust it and you are good to go! Pictures should be attached showing a few of the steps. Might explain things better than my typing, then again my drawing isn't so flash haha.
My Dad is the genious behind this. He has had to do it before back in his farming day. So full credit to him!!
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