How To Make Throttle Cables For Motorcycles

In this video I show you how I made the throttle cables for the BMW R80. I show you every step in detail. How to route the throttle cables, determine the right length of the outer tube and Bowden cable, how to choose the right ferrules and nipples, how to solder the nipples to the Bowden cable, how to lube the Bowden cables, and how to install everything on the motorcycle. I have also built a DIY bird caging tool and honey pot, to make the process as professional as possible.
📋 BMW R80 Build Sheet - Get links, prices, and notes for all the parts on the BMW
geni.us/BMWR80...
Bowden cable shop - www.bowdenzug2...
End cap crimp tool - geni.us/bowden...
📋 My BMW R80 Wiring Diagram
geni.us/BMW-R8...
🧠 COURSES
✍️Learn how to TIG weld from one of the best! (This is how I’ve learned)
pacificarctigw...
🦾 Here is a course that helped me to understand the basics of fabrication when I started building my first parts. If you’re new to fabrication I’m sure it will help you too. With the link below you’ll get $50 off of your first course at HP-Academy.
geni.us/HPAcademy
🛠️ MY TOOLS
COMPRESSOR - geni.us/compre...
RATCHET SET METRIC - geni.us/ratche...
RATCHET SET STANDARD - geni.us/ratche...
SCREWDRIVERS - geni.us/screwd...
POWERFUL CORDLESS DRILL - geni.us/dewalt...
TOOL CHEST - geni.us/tool-c...
MOBILE WORKBENCH - geni.us/mobile...
TORQUE WRENCH BIG - geni.us/torque...
TORQUE WRENCH PRECISE - geni.us/torque...
FAV BLOWTORCH - geni.us/blowto...
🔬WELDING
MY TIG WELDER - geni.us/tig-200
MY MIG WELDER - geni.us/mig-200
WELDING GLOVES - geni.us/mig-ti...
🖨️ 3D PRINTING
MY 3D PRINTER - geni.us/3D-Pri...
MY CAD PROGRAM - geni.us/CAD-Pr...
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⏰ TIME STAMPS
Your particular motorcycle may be different so take this as a suggestion rather than any kind of rulebook.
I hope you're having a great day. - WRENCH ON!
JOSHUA

[@SimonFoster_LG_TVS]

brilliant video the bird caging and honey pot have now sorted me thank you

[@HeavyMetalParkingSpot]

I really appreciate that you take your time to do the research before jumping in. I think that is one of the reasons your end-results always looks so darn professional. Great job!

[@MotoWrenchers]

Thanks for the kind words. I try to do my best. Still a lot of room for improvement...but it would get boring without :D

[@HeavyMetalParkingSpot]

@@MotoWrenchers Yeah, you are never "done" when it comes to that. But one step at a time. And as you said, without room for improvement life would get boring!

[@andyberhaahn]

Thanks for all the tips! Sure to make my cable process easier

[@MotoWrenchers]

You’re very welcome. Let me know how it goes 👌

[@MotoWrenchers]

I’ve just learned today, while making the clutch cable, that it’s good to carefully sand the end of the wire and to scratch up the inside of the nipple with a stainless steel brush. After that, dip both parts in acetone to clean, before proceeding with the bird-caging and solder process. One or two test-runs definitely don’t hurt 👌

[@AaronStrumpel]

So cool!

[@MotoWrenchers]

Thank you my friend! I appreciate it 🙏

[@bjornjohansson4911]

Brilliant! So good tutorial. Thanks. 😀. Swedish regards

[@MotoWrenchers]

Tack, tack! I appreciate it my friend. You probably also have a 'fake' summer like us in Northern Germany. 14 degrees and rain from the side :D More time to be in the workshop. What are you working on?

[@bjornjohansson4911]

@@MotoWrenchers Just about the same sort of summer here. I bought another bike last week, that has some minor issues. It is a 2003 Royal enfield Bullet 500, that I fell in love with. The "gas wrench" is not 100%, so I suspect the throttle cable. Maybe it only lacks of lubricant, but there is a quite sharp bend from the carburettor beneith the tank where the path is very restrictive. There are more small things to do, but I have no hurry. I can't resist riding her. I love the sound. Single cylinder, and no cathalyst makes it loud and creates glances. 😀

[@MotoWrenchers]

@bjornjohansson4911 dude, that sounds like an amazing bike. I love single cylinders as well. The sound is soo nice. I hope you can get the Enfield running soon 🤩 Let me know how it’s going. If you want, shoot me a message on Instagram with a few pictures. Would love to see the bike. Cheers brother!

[@michaelelse9328]

The Moto Wrencher Academy goes Alchemy..... 😂👌🏻 You really seem to think about your projects very carefully in advance. That's why it looks like you've done it a thousand times before...

[@MotoWrenchers]

Hahaha 🧪👨‍🔬 Yeah, but that is a double-edged sword. Sometimes my perfectionism leads to overthinking which sometimes holds me back but I’m getting better and better at just starting and experimenting after the basic research is conducted 🧐

[@michaelelse9328]

Take courage my friend... And always keep an eye on the Ride Wrench Life Balance.... Thanks for the personal insights...​@@MotoWrenchers

[@Hernandez9699]

Richtig nice! Werd jetzt auf jedenfall alle züge an meinem bike selber machen Hast du tipps wie man den richtigen durchmesser findet? Oder gibt es da standards bei gaszug/kupplung/bremszug?

[@MotoWrenchers]

Nice! Gut, dass du das fragst. Das habe ich scheinbar vergessen zu sagen. Also für Gaszug nimmst du am besten 1,5mm 7x7 und für die Kupplung habe ich 2mm 1x19 genommen. Für Bremszüge kann man auch 2mm oder sogar 3mm 1x19 nehmen. Bowdenzug24.com ist ein sehr nicer Onlineshop. Viel Erfolg! Und solltest du noch weiter Fragen haben, sag gerne Bescheid.