Throttle cables selection

[guzzifan]

I have an 850T that has a 1000cc with PHF 36’s installed and a Thommaselli 2C throttle.  I need the right cables to connect the two.  The bike had VHB’s and the 2C and that used two cables about 40” long with some nice angled adjusters near the throttle.  Fittings on both end of these old cables fit both the 2C and the PHF slides.

I had hoped to use the same cables but the PHF’s connect to the cable much further down the carb…nearer the bottom of the slide as opposed to the top for the VHBs, so I need a bit more length…like a good 3 inches. 

MG cycle sells such a cable 43” long but without the angled adjuster part (it has a straight adjuster a few inches downstream of the throttle end) that is retained by the 2C wire clip so I am not sure the throttle end has the groove where the wire clip would go, although the add says they are for the 2C.   Also, my concern is that the 43” cables, although 3 inches longer, since I want to add a 90 degree elbow fitting will eat up some of the available free-play that I need to accommodate the lower slide attachment point.

My questions are…
1). Does the addition of the 90 degree carb-top elbows eat up much free play?
2). How much free-play do I need from carb top attachment (where the cable meets the carb top fitting) and the end of the cable  for PHF 36’s?

I thought to be on the safe side I may buy the 46” ones and shorten accordingly…

Thanks!

[Scout63]

Do you need more overall length, or more inner cable length?  If the overall length is ok and you need more free inner cable, I’ve had success prying off the lower cable sheath cap and cutting back the cable sheath a few inches, then sliding the cap back on. If you need a longer overall cable, I would go to MG Cycle and find a cable with the right fittings at both ends in the length you need. Good luck.

[guzzifan]

The cables I have may be the right outer cable length cable length, but the inner cable is about 3 inches too short.

MG Cycle offers a 43” and a 46” and I think the 43” would work for overall cable length, which I assume is the inner cable, but I am concerned that once I add the 90 elbows to the top of the carb I won’t have enough free play unless I shorten the outer cable.  I have plenty of solder-on carb-end fittings, but no throttle-end fittings, so I could get the 46” cables and shorten them…always a tricky operation to get the perfect length though.

Does anyone know how much free play the 90 degree carb elbows use up? 

[guzzisteve]

You have to buy the stuff then cut to fit. They don't make cables for that combination of components. I used 81 G5 cables cause they are for PHF carbs. Measured the throttle extra sleeve & adjuster length for throttle & or 90* elbow. Then cut the spiral outer to fit. I never wrote down how much, it's trial & error. I have some 90* elbows to measure in my new carb parts. I'll be back. 

Elbow's are about 1 3/4" with adjusters screwed in w/locknuts, not counting the threads that screw into carb tops & locknuts.
Make your outer sheaths long so you can cut to fit, put it all together & see how far up your slides are from stop, cut that much off outer next time.
AND it's like Scout says, unscrew chrome cap, cut black plastic, unravel outer sheath, snip, cut inner nylon coating. Do all this w/o damaging the inner cable. I use a file to the end of outer sheath so it doesn't scrape the inner cable.
If this is your 1st time making cables, order 2 or 3 sets
Good Luck, have fun. There is an art to it.       

[cliffrod]

I just installed new cables (recommended on their site, forget the actual length) and added 90degree elbows from MGcycle on the phf30 carbs on my CX.   No splitter.  The long cables are almost too long, with adjusters on elbows needing to be almost completely extended. 

Inner Cables could be easily shortened.  Sheaths are plenty long as well.  If you need parts to modify, those would be adequate imho.

[guzzifan]

Just as I figured…order long and cut to fit. 

And now for another question regarding the 90 degree elbows..do you think they for those with them, do you think they are they soft enough to fill with sand so they don’t collapse and put in a vice and straighten a bit? 

90 degrees is too much bend for my installation and  I know there are 50 degree ones made but I can’t find a Canadian supplier for them and everything else will include a 35 Euro shipping cost.  MG Cycle has 90 degree ones and I need to place an order for some other stuff so I am thinking of buying 2 and straightening them a bit…if you think they will not break first.  If you have some less-than-90 degree ones lying around I am interested in putting them back on the road.

And while I am here…anyone with non-belcrank 36’s on a Tonti…do you have the elbows on the cable installation and if so how much of a bend?  A picture would be very nice.

Carb cables are the last piece to go before I fire up the fresh engine.  This is starting to get interesting! 

Thanks

[tris]

If you're in the UK you might give Venhill a shout

https://www.venhill.co.uk/bespoke/cables/