I just put straight drag bars on my 1980 xs650 special and now the cables have too much slack. I figure I need a clutch cable around 42 in and a throttle cable around 36. Does anyone know where I could find cables at the right measurements I’m having a bit of trouble.
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Clutch and throttle cables
- Thread starter Derekvs
- Start date
Your bike had pullback bars as OEM. OE PN is 3L1-26311-01-00 throttle and 3L1-26335-00-00 clutch.
1977 XS650 had shorter bars. OE PN 584-26311-10-00 throttle and 447-26335-00-00 clutch.
The 1977 throttle cable is NLA and 1010 mm long. I doubt that one clutch cable is different from the other.
Motion Pro has XS650 cables 05-0012 and 05-0013.
I believe the best course of action is to get creative in using up that slack.
Since I still have the Special bars on my bike, I have not had to contend with the issue and have little to offer.
Yes, careful rerouting is about your only option short of having custom cables made (expensive). I put lower bars on all my bikes, but not as low as drag bars. On the couple bikes I've put them on (for other people), I found cable rerouting to be pretty difficult. Those drag bars are just too low and narrow. Honestly, I'd recommend something else, lower than stock yes, just not that low and narrow. I run Euro bend bars on all my bikes. They only have about a 2" rise but cable rerouting is usually pretty easy .....
You can make your own cables, it isn't hard. All the bits and pieces are available here: www.flandersco.com. Flanders has been the go-to source for cables and cable making supplies for many decades.
I'm doing some digging around on Flanders... Going to buy a bunch of stuff to make my own throttle cable. What's the difference between "strands" one offers a 7x7 strand throttle wire and another option available is a 1 x19 strand.
Another question is this: the most common size cable used for throttles, clutches, etc would be 5mm O.D and 2.3mm I.D.. right..?
There should be metal caps on the ends of these cables. Will they simply get glued on when I install them or crimped? I just want to make sure I get everything I need on my first try. Lol
7x7 is 7 groups of 7 strands. 1x19 is one group of 19 strands.
I'm running straight drag bars, I ordered a motion pro cable, and it was too short. By about an inch.
PN was 05-0012. The ferule at the end on the carb side was also too small to fully engage the hole it was supposed to rest in.
PN was 05-0012. The ferule at the end on the carb side was also too small to fully engage the hole it was supposed to rest in.
Could they have put the wrong cable in the package? I have that cable on my bike and found it plenty long for stock Special bars.
I suppose it's a possibility. I'll have to check on Tuesday when I'm back at the shop. I entered in the stock Yamaha throttle cable part # on their search and it brought their cable right up. It was almost right... So I'm wondering if I made a mistake somehow. Either way, making my own cable would be a cool learning experience.
Nothing against Flanders but another option is:
https://www.venhillusa.com/cables-and-components/universal-cable-kits.html
I used one of their kits when working on I believe it was a XS400 years ago.
https://www.venhillusa.com/cables-and-components/universal-cable-kits.html
I used one of their kits when working on I believe it was a XS400 years ago.
It might be a nice thing to document on this forum.
This looks way easier to navigate! I think Flanders is probably pretty good too but they make it a lot easier providing the whole kit. That ensures I don't miss anything.
I could make a video when I do it. I can also put it on my build thread with step by step. These older parts are going to get harder and harder to find. Eventually building your own components will be the way to go.
I've done a fair bit of custom builds, have yet to find the need to invest in the tooling to make cables (and I prefer to do most things in-house). I have always been able to use stock or modified stock cable. Then there is the ability to order one-off cables from Motion Pro or Venhill.
Anyway, Revival (ATX not FL) offers tools and supplies too:
https://revivalcycles.com/collections/motorcycle-cable-kits/products/diy-cable-bundle
https://revivalcycles.com/collectio...cycles-signature-universal-throttle-cable-kit
https://revivalcycles.com/collectio...s/products/revival-signature-brake-clutch-kit
You're the man! I appreciate all the leads for supplies and parts! I plan to have my first ride on the fresh build VERY soon. Gotta get a read on the plugs and see how the carb is set up under load. I can't wait to document the experience.
Just my 10p worth (5c) I use VENHILL cables and have done so for years.
Great quality and super slippy cable in housing. They are also very flexible and strong.
Easy to build your own cables to suit.
Web: https://www.venhill.co.uk/
These are good videos by REVIVAL:
The above guides work.
Ads.
Great quality and super slippy cable in housing. They are also very flexible and strong.
Easy to build your own cables to suit.
Web: https://www.venhill.co.uk/
These are good videos by REVIVAL:
The above guides work.
Ads.
I have Honda SuperSport bars, approximately 1 1/2" lift and 28" on my '77. While fitting the bars with the tank off the bike and fully ignoring the original routing I found a way to make each work very smoothly. As others point out make your bends to the cable to the greatest radius possible. Loosely tie the cables in place and remount your tank. Check the action of each cable. You may have to try 2 or 3 different routes. Good luck.
That's the problem with the drag bars - they're too low and narrow. That doesn't leave much room for cable routing and you end up cramming stuff in. Why do you want drag bars anyway? If you're doing it for the "look", then I guess you'll just have to deal with the consequences, lol (the cable routing will be bad and they will be uncomfortable). $222 for that DIY kit, I can buy lots of cables for that, lol.
