need help - mechanical gauges to electronic? - '77 lemans problems

[amamet]

I remember having issues snapping numerous speedo and tach cables on my 77 lemans when it was on the road in '13 before the restoration.  its all back together now and can't seem to get a smooth curve up to the gauges because of the headlight being close to the bottom of the gauge pod.  usually the cables snapped where the headlight forced a harsh bend up to each gauge.  is it just me?  im sure it worked well at some point, just never for me. I can't get the headlight installed without bending each of those cables severely which also made the gauges inaccurate because of stress on the cables.  I do remember that, they were "jumpy". I tested each gauge with an impact gun in reverse and a square bit (I don't know how else to test them) and the needles operate smoothly.  I love the original Veglia gauges with its 65k miles on the odometer but if I can't get it to work im going to have to come up with something else. like I said im sure I can't be the only lemans with gauge cable issues with the factory headlight.  maybe im just doing something wrong. advice? pictures?
thx
allen

[Don G]

So, how fast does your impact go according to your Veglia?  DonG

[rtbickel]

I seem top remember, although it was years ago, that you could get a 1:1 90 degree adapter to put on the end of a speedo drive to overcome that problem.

[bodine99]

Might check with Barnett Clutches & Cables 805-642-9435. about sending them your cables and inquire if the can put 90 degree ends at the clocks end. If you have room

[Antietam Classic Cycle]

I went through the whole cable bend issue with Jim's/Ted R's Le Mans. The original (US) Aprilia headlight makes it difficult to route cables without too much of a bend, even with cables that already have the angled metal end. I tried the 90* drives, but then the cable was too long and routing was still problematic. The decision to go with a European type headlight (actually from a V65) helped - a bit of extra space at the back. Still not optimal, but seems to work okay.

[Aaron D.]

It looks like you now have the Euro style headlight setup. The original US style has the headlight pushed out a bit which may be the problem with routing.

[amamet]

Hmm. I’ll check it out charlie.  Just looked on eBay for reference, the v65 that I found there looks the same as the others except one that has a smaller, rounded bucket.  Aaron, the bucket is the same, just the ring isn’t as “long”. Then bucket is the issue.

[amamet]

I do have 1 90 degree adapter in my parts stash, and yes, it makes the cables too long. Thought about using the adapter and swapping the tach and speedo from left to right to see if that worked

[wirespokes]

I can shorten the cable for you if you decide to go that route. Making the outer sheath shorter is easy, it's forming the square drive that's fun.

[moto-uno]

  There's an aftermarket company called Century that makes universal inner speedo ( or tach ) cables that worked well on my Le Mans 2 . Also the
90 degree fitting was pretty much a necessity with the stock setup I found . And maybe buy 2 kits , as it's kinda easy to get the first attempt wrong  .  Peter

[amamet]

I may have solved it, I say may because I dont have plates yet so can't take it past a few blocks from my house to test it out.  I always tried to figure out how to route, bend or use adapters for the cables or adjust the headlight when I should have really looked at the gauge cluster.  I raised the cluster about 6mm with washers off the perches, this way its not so close to the headlight bucket. they still hit the bucket but the bends seems to be significantly better.  the bucket isn't rare by any means, so I "manipulate" the back of it so as to give even more room to the cables

[SIR REAL ED]

I may have solved it, I say may because I dont have plates yet so can't take it past a few blocks from my house to test it out.  I always tried to figure out how to route, bend or use adapters for the cables or adjust the headlight when I should have really looked at the gauge cluster.  I raised the cluster about 6mm with washers off the perches, this way its not so close to the headlight bucket. they still hit the bucket but the bends seems to be significantly better.  the bucket isn't rare by any means, so I "manipulate" the back of it so as to give even more room to the cables

I was just about to suggest the same, only I was thinking 3/4".  I don't know anything about your mounting system, but sometimes a bend in a bracket here or there helps.  Now idea at what point your components will start looking "funky."  Or if you are trying to preserve an original look.

I changed the angle on my KTM dashboard by 35 degrees to eliminate glare.

Could you modify the headlight mounts to move the headlight down and/or forward as well?

really creative/imaginative/mutilative would be drilling two holes in the headlight bucket and running the cable thru both holes.  Or cut a groove in the back of the headlight bucket for clearance.  Solder in a semi-circle length of tube to seal?  Cable length might not let it fly.

[Antietam Classic Cycle]

the bucket isn't rare by any means, so I "manipulate" the back of it so as to give even more room to the cables

Actually it is a bit rare. It's not the same bucket as used on the T/T3, etc. AFAIK, it's only used on the Le Mans.

[steven c]

On my 77 I just gave up and mounted a sigma bicycle speedo.

[amamet]

It is rare? Crap. Thought it was the same as my other ones. Oh well