wire in the throttle cable too short

i have a feeling there's a simple answer to this that will make me look stupid. bt anyways. i'm replacing the throttle cable. but the actual silver wire inside the cable is about 1/2 an inch short. is there a way to resolve this. in my minds eye i can picture stripping the cable that approximate 1/2 inch somehow. but then i would have to somehow cut through the metal cable that surrunds the metal wire.

am i thinking right or am i totally missing something?

 

Just a quick thought.
Did you dial your cable adjuster back into the lever perch?

 

well...if you're talking about the part of the cable that has the thing you can twist, yea i tried that. at the furthest it's 1/2 inch too short.

is there another adjuster somewhere? maybe i should take a picture tomorrow and add to the thread. i'm a newb with terminology still

 

Have you got it going round in the right direction in the twist grip?

 

uzi, don't know if you did this but, during my rebuild I had the enrichment cable & throttle cable off. When I reinstalled them at the engine end I had the same problem on my throttle cable, 1/" short. What I had done was hok the cables up to wrong location, had the ec going to the carb throttle arm & the throttle cable going to the ec arm. I switched them around & problem was solved. Thanks to Bigfitz on that one.
Gregg

 

or you got the wrong cable. Take the new one and lay it side-by-side with the original. Compare the overall length (the inner wire) and push the outer against the same end on both and compare the length of the outer cables as well.

If you're CHANGING (to a longer or shorter cable) the "free length" (the difference between the sheath and the inner cable) has to be maintained or at least be close enough to be adjusted out. chacal and I went thru this figuring out a shorter clutch cable when I went to lower bars on my 550s.

 

How long is the inner wire suppose to be from the outside insulation, I just tried this today and my wire is about 1/2 too short also. I hook the wire in the throttle and the insulation cap doesnt fit in to the bracket. Any suggestions?

 

Go to a Bicycle Store and have them make you a Brand New Cable with Aluminum Cable Stops >>> And >>> a Micro Adjuster for Short Money.

A serious Bike Store.
You can do the whole thing yourself.

You need to to be able to solder a New Bronze Bullet on the wire.
Get the right sized Bullets.

 

Hmm maybe I should give that a try.

 

forgive me for asking this you installed it correctly by hooking it into the throttle linkage before trying to slide it into the cable holder on the carb side then adjusting the remaining slack at the handle side?

 

I actually tried to install it in the bracket FIRST, Was this incorrect? I thought the insulation was half inch longer then what its suppose to be but someone please let me know how to install this correctly so I can ride PLEASE

 

Get it installed at the twistgrip FIRST (in place, all adjusters screwed in fully, not adjusted.) Then get it hooked up and into the bracket on the carbs. Then adjust. Check at full steering lock in both directions that there is still a little bit of play.

 

If I did it the other way (carb bracket first) is it possible to still be short?

 

Sure its possible. It might be the wrong part. Some PO trying to make-do with something that don't fit.

You could have the Cable routed incorrectly.
That will cause you to lose some length.
The Throttle Grip might be incorrectly positioned.

Install it and pull the Cable Sheath down to where it fits in the Carb Bracket and keep it snugged into there with "Squares" of Duct Tape used to hold the Sheath from shifting.

If you can't get that Cable to fit. Fabricate a NEW one.
Any decent Bicycle Shop should be able to MAKE you a new one in 15-Minutes.
You can buy the Materials and do it yourself.

The Sheath can be "Cut-Clean" with a Dremel Tool and a Cut-off Wafer.
The Sheath ends can be "Grinded-off" but it heats-up and melts the covering.
You can Hack-saw off the ends ... but, the Sheath is tough Spring Steel.
You can 'Clip-off" the ends if you insert a Drill-bit Shank to keep the Sheath from kinking and pinching at the Cut.

The cleanest cut is with the Dremel Tool and Cut-off Wafer.

The Cable COMES with one end fitted with a Lead Bullet.
You have to Solder one on the other end after you put on Cable Sheath ends and MEASURE.
A Dremel Cut-off Wafer cuts Cable ... clean and neat.

Heat THE CABLE.
Let the Solder run down into the Bullet.
When it cools ...
Shape the Solder into a PERFECT Bullet End by sanding the Solder using a Dremel Tool or a few NEW Fingernail Emery Boards.

 

I will try and return it and if that doesnt work I will go the a good bike shop.