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HOW TO - Cable Replacement
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HOW TO - Cable Replacement
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monza



Joined: 26 Mar 2007
Posts: 343
Location: Kansas City

Post HOW TO - Cable Replacement Reply with quote
Ok, so here is a real short howto on cable replacement. This should hopefully illustrate how easy it is to replace a cable.

On my scoot, a selector cable went bad, so I went to my dealer and got a new one. It was real expensive. A whole $3.50. Ouch. (J/K)

First you have to take the mirrors off, and then the 4 screws that hold the headset cover on. Then, for this repair, I had to remove the selector box cover and loosen the pinch bolt on the cable. I then pulled the cable out of the outer sleeve and discarded. The new cable was lubed up with some teflon EP grease that I had. Some people like gear lube or oil. I would think that most nearly any lube would be good (please chime in if you have an opinion on this). You then thread the inner through the sleeve and it should pop out the other end. If you have difficulty getting it through, then you may have a bad sleeve. The new cable then needs to be terminated on the pinch bolt. Adjust the tension in the cable as required. This procedure should be good for the selector, brake, and clutch cables. The throttle cable is slightly different in that you have to un-screw the top of the carb to release the old cable from the slider.




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-Paul O.

75 Vespa Primavera "Parmakit 130", P200E,
Fri Oct 12, 2007 1:36 am View user's profile Send private message Visit poster's website
mc



Joined: 27 Mar 2007
Posts: 152
Location: Milwaukee, WI

Post Reply with quote
Nice! Thanks for taking the time to post this, Monza!

I'm shamed by how clean your scoot is from filth and crud. Embarassed

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Monica
Fri Oct 12, 2007 3:05 am View user's profile Send private message
xcruckx



Joined: 17 Oct 2007
Posts: 135
Location: Columbus OH!!

Post wiggle room Reply with quote
So the wiggle room, that should be in the handle right? not anywhere else?

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Wed Oct 31, 2007 3:44 am View user's profile Send private message AIM Address
Scotter



Joined: 26 Mar 2007
Posts: 59
Location: San Diego

Post Reply with quote
Thanks, Monza. This thread is timely. Believe it or not my shifter cable broke yesterday while I was on a work lunch break ride. I limped it back to work in 1st gear. Damnit, I had been meaning to buy some extra cables in case something like this happened. I work about 14 "heavy traffic" miles from home and thought I might have to limp the whole way home in first gear. I had absolutely no time to search this forum while at work but did have just enough time to send out an E-mail to a few local scooterist for help. "Jully" from this forum called me up and drove out with tool kit and extra cables. Scooterists RAWWKK!!

And the whole process is pretty much how you described. The scoot is now running like nothing ever happened. Chetaks RAWWKK!!
Wed Oct 31, 2007 3:51 pm View user's profile Send private message
average joe



Joined: 04 Apr 2007
Posts: 257
Location: Jersey Shore

Post Reply with quote
How do you adjust the cables after installing new ones. Just pull them tight, or is there a procedure to follow ?
Thu Apr 10, 2008 11:28 pm View user's profile Send private message
Owsley9



Joined: 05 Mar 2008
Posts: 214
Location: Birmingham, AL

Post Reply with quote
average joe wrote:
How do you adjust the cables after installing new ones. Just pull them tight, or is there a procedure to follow ?


I'm not sure if this is the correct way to do it, but it worked. I had a friend hold the shifter in line with neutral, while I pulled the cables tighter under the engine. If you don't have a friend to help, tape the shifter down, so you keep those handy numbers in line!

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Fri Apr 11, 2008 12:54 pm View user's profile Send private message Visit poster's website
monza



Joined: 26 Mar 2007
Posts: 343
Location: Kansas City

Post Reply with quote
yup, pull them tight...for the shifter...

The clutch is more of a balancing act in getting the right amount of grab without too much slip...brakes too...

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-Paul O.

75 Vespa Primavera "Parmakit 130", P200E,
Fri Apr 18, 2008 1:56 am View user's profile Send private message Visit poster's website
mpa5858



Joined: 07 May 2007
Posts: 129
Location: Chicago, IL

Post Ordering Spare Cables Reply with quote
Hi everyone,
I want to place an order for spare cables (front/rear brake, shifter, throttle, clutch) from Scooter Parts Direct. Most of their cables indicate that they "fit most models," suggesting they're of a standard size. Is this a pretty safe bet for my 2006 Chetak?
Thanks!
mike

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Mike
2006 Jade Green Chetak
Sun Jun 22, 2008 3:28 pm View user's profile Send private message
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
I would order Bajaj cables from a Bajaj dealer.

Why?

They're made out of stainless steel and they last forever.

Most of the cables you can get from ASC, Scooterworks, or SPD are softer material and will not last as long.

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The "X" stands for ex-Chetak owner.
Mon Jun 23, 2008 2:58 pm View user's profile Send private message
mpa5858



Joined: 07 May 2007
Posts: 129
Location: Chicago, IL

Post Reply with quote
matty_x wrote:
I would order Bajaj cables from a Bajaj dealer.

Why?

They're made out of stainless steel and they last forever.

Most of the cables you can get from ASC, Scooterworks, or SPD are softer material and will not last as long.


D'oh! For whatever reason, I hadn't even thought of simply ordering Bajaj parts! And I had no idea there'd be a difference in quality. Thanks, Matty.

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Mike
2006 Jade Green Chetak
Wed Jun 25, 2008 1:13 pm View user's profile Send private message
cowboydoug



Joined: 21 Jun 2008
Posts: 258
Location: ST. George, Utah

Post 4th Hand Tool Reply with quote
is a 4th Hand Tool needed, recommended for tightening cables & making adjustments?
I haven't seen it mentioned here so I am curious.

Is there a difference in the quality of this tool, or does anyone have a good quality
one they can recommend? I hate buying cheap tools, only to have to replace them
at a later time with the one I should have bought the first time.




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I moved to Utah for fly fishing and the big haired girls...
-the fly fishing has been very good to me...
Mon Jul 28, 2008 3:23 am View user's profile Send private message Visit poster's website Yahoo Messenger
xcruckx



Joined: 17 Oct 2007
Posts: 135
Location: Columbus OH!!

Post Reply with quote
if you are doing cable adjustments for the clutch i'd recommend it, i hated doing it by myself without one, I had to get my friend to help me out by pulling it tight while i did the adjusting.

I think a 4th hand tool is only 20 bucks at most, and worth it if you are alone and sans-friend.

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Lift the head light assly.

the mysterious PWR/NORM buttons...
Mon Jul 28, 2008 7:50 am View user's profile Send private message AIM Address
hkabik



Joined: 12 Apr 2007
Posts: 50

Post pinch bolts on cable Reply with quote
Is there a secret to loosening the pinch bolts? When I try to turn them, the whole cable just kind of turns in the same direction.
Mon Jul 28, 2008 9:47 pm View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
No secret, just grab the body/barrel with a pair of plies so you can hold it firm while you put a wrench on the pinching bolt.

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Mon Jul 28, 2008 10:15 pm View user's profile Send private message Send e-mail MSN Messenger
Owsley9



Joined: 05 Mar 2008
Posts: 214
Location: Birmingham, AL

Post Reply with quote
blahhhhhhh. Of course the day after I took my tools out of the scoot to do an inventory, a damned shifter cable snapped on the way home from work today. I limped back to work and luckily was able to get into the maintenance shop. I only had a clutch cable, and the end is too big to fit into the slots, but I made it work to get me home.

I guess I know what I'm doing Saturday morning!

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Wed Oct 15, 2008 11:49 pm View user's profile Send private message Visit poster's website
dirkhunt
Guest





Post Reply with quote
Does anyone have any tricks for feeding the throttle cable sleeve? or the rear brake sleeve?

As a note for feeding the front brake cable sleeve start at the bottom and push it up
Tue Dec 30, 2008 5:19 pm
Plotts



Joined: 27 Jun 2008
Posts: 52
Location: Chicago

Post Legend speedo cable and sleeve replacement Reply with quote
I had to replace the speedometer cable and sleeve on my Legend today. At first glance I thought this was going to be impossible the way the cable goes through a tiny hole in the steering arm.

Here's what worked for me.
Remove the dash and disconnect the upper and lower speedo cable nuts. I removed the inner speedo cable from the top. I then cut the lower cable end off and stipped back the pastic to expose the metal coiling underneath. Next I took some picture hanging wire and fed it about an inch up the empty sleeve. Bent over the sleeve to separate the metal coil and fed the wire up through the small gap. I twisted the wire together at the bottom and pulled the old cable out through the top with the picture wire attached.

On the new cable you can remove the lower end nut and plastic retainer, do so. I repeated the process of attaching the picture wire coming up through the frame to the new speedo cable sleeve (without trimming, just bend it over near the end). Near the wheel where the bottom of the wire comes through the steering arm, I slowly pulled the picture wire while pushing the new cable down from the top. It was a little tough to get the new sleeve to come through the little hole, but it worked. Hooked everything back up after re-installing the end piece and nut and now it works great. Hope this helps if anyone has to replace their speedo cable AND sleeve. Obviously if the sleeve is OK you can simply replace the inner cable without removing the sleeve.

Cheers!
Tue May 19, 2009 12:24 am View user's profile Send private message
DMH



Joined: 25 Jul 2009
Posts: 1

Post Shifter Cable Questions Reply with quote
A couple of weeks ago, I was riding along on my '06 Chetak (lifetime mileage: roughly 1,200) and found that it was very difficult to downshift my way back from higher gears to lower ones and neutral. It seemed like the tension on the shifter cable that tightens when turning the shifter backward/clockwise had loosened considerably. As a result, I had to force the shifter control back well beyond where I would normally find neutral and then first gear in order to shift to either. I was able get the bike back home, but haven't gotten it back on the road since.

My questions are:

1. Does it sound like one or the other of my shifter cables need to be replaced or just require adjustment? I would assume the latter, since neither cable is broken, wear has been minimal and I can see that there's tension exerted by both shifter cables when I rotate the shifter back and forth.

2. I might have been able to correct the problem by simply adjusting the tension on the cables where they attach to the top of the gear shift assembly; instead, I opened up the assembly to get a look inside. Having done so, I can see how the shift lever engages gears but I'm having a hard time seeing what position it should be in when the scooter is in neutral, or how the shift lever inside the assembly disengages gears to return to neutral.

To adjust the cables properly, it seems like I need to start with the shifter in the neutral position then tighten both cables, but I can't tell how the shift lever should be positioned at that starting point.

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Mon Jul 27, 2009 6:30 pm View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Re: Shifter Cable Questions Reply with quote
1. Yes, it sounds like one of your cables has slipped its adjustment. When this happens you should look at ALL THREE cables. The two on the shifter and also the clutch. They all must work in harmony.

2. To adjust the cables properly, yes you do have to figure out 'where you are at'. To figure out where you are at you must jack the rear tire off the ground. As soon as the rear tire is spinning in the right direction you can manually move the round shifter plate. Yes, this will require two people, or three. One to spin the tire, one to use clutch lever, and one to shift. You will soon move the shift plate into neutral, or 1st, or 4th.

3. It seems logical that Neutral would be the 'middle' position of the shift cables. Do not assume so. One of those cables MUST pull the shift plate firmly all the way from 4th into 1st, the other MUST pull the shift plate firmly from 1st into 4th. Neutral is sorta somewhere in between. Neutral can be found using either cable.

With help you can figure out how the cables move/pull the shift plate. Then you can set them to get you into 1st and 4th smoothly. You do not need lots of tension on them, just gently remove the slack. Test ride. Adjust. etc.

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Mon Jul 27, 2009 7:14 pm View user's profile Send private message Send e-mail MSN Messenger
scootermike



Joined: 25 Mar 2007
Posts: 525
Location: portland,oregon

Post Reply with quote
this all sounds good but I just spent 3 hours trying to adjust my shifter cables I get from 1 n 2 3 no 4th any ideas? I will try again tommorow just fustrating
Sun Oct 25, 2009 5:10 am View user's profile Send private message Visit poster's website
dirkhunt



Joined: 15 Oct 2009
Posts: 173

Post Reply with quote
Sounds like you have the cables are pulled too far one way or the other, may also be too much play in the cables. I had the same thing with first when I did my once a year "all of the cables " adj & Tighten. snugged my shifter right out of reaching 1st.

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Mon Oct 25, 2010 7:04 pm View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
Are you turning the rear wheel while attempting to shift ??? The tranny "thinks" it is being used while you are shifting it. Find 1st then 4th, each with a bit of slack, and snug thing up from there. Although I'll admit, it's much easier said then done Embarassed
Tue Oct 26, 2010 12:42 am View user's profile Send private message Send e-mail MSN Messenger
scootermike



Joined: 25 Mar 2007
Posts: 525
Location: portland,oregon

Post Reply with quote
thanks guys only a year late on replies I got it thanks anyways Very Happy
Tue Oct 26, 2010 5:22 am View user's profile Send private message Visit poster's website
dirkhunt



Joined: 15 Oct 2009
Posts: 173

Post Reply with quote
We're nothing if not punctual....

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See now, this is why mad scientists are generally less desirable than your common or garden variety scientist.
Tue Oct 26, 2010 1:08 pm View user's profile Send private message
danman1178
Site Admin


Joined: 25 Mar 2007
Posts: 336

Post Reply with quote
I know its late.. But next time someone replaces a cable... could we get photos for the site??? I thought someone had done that ... I cant find them tho..
Sat Jun 30, 2012 3:46 am View user's profile Send private message
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