Maintenance - Cheap repair of clutch or throttle cables - Version 1 - Check updated video

[@markbutler9046]

Brilliant idea with the wood mold. I was racking my brain on what to use as a mold. 😊

[@FARANDFURTHER]

Yep, it worked, someone in comments suggested the aluminium but wood was easy to work with. I need to test the flux & other material when I'm back from Albania, I have one clutch cable to fix....

[@markbutler9046]

@@FARANDFURTHER My throttle cabe is working great! Saved me a buch of money and time. ! P.S. I frayed the end just alittle in the mold, so it will nevet slip out of the solder agin.

[@nightster6378]

Hi Good job, a couple of suggestions - As a mould you can use Aluminium the same as you did the wood but you get a better finish and if you drill a 3mm through before the 6mm hole for the nipple then you can hit it out with a punch and dress it up. I would also suggest fraying the cable slightly as the unfrayed cable could pull through. You could also consider soldering the nipples supplied in the kit rather than the screw as this would be more permanent. I do mine using a solder pot and use Bakers Floid No3 as flux which is a liquid. Can I ask what flux are you using? Thanks.

[@FARANDFURTHER]

Hi Nighster, I made the new updated video about the clutch cables and incorporated your feedback! Thank you so much for your suggestions.

[@FARANDFURTHER]

Updated version: Yamaha Ténéré 700: How to DIY fix clutch or throttle cables for cheap and anywhere in the world? kzbin.info/www/bejne/aXTJh6CKptN_gdU Hello everyone, I made an updated video about fixing the clutch or throttle cables. Incorporating the feedback from many of you and also including some new tools and hardware.

[@azlong4596]

If you fray the end of the cable about 1-2mm then make your solder fitting you get a much stronger tip. Also you need to maintain cables at least every 10K mile or more often depending on the terrain and weather you are traveling in. There are cable lube tools made for the purpose, are not expensive and easy to use. Also cables normally break at the end because the fixture doesn't rotate during actuation. Fit, lube and check the levers for fluid movement often.

[@FARANDFURTHER]

You're 100% right. The maintenance is very important indeed. I usually have problem with the fixture not rotating enough and the cable breaks right there at the lever.

[@eforiedintulcea]

Looks nice. Do you have some feedback one year later on how the soldering ends lasted?

[@FARANDFURTHER]

The thing which I didn't know is what @Nightster recommends in other comments... I need to use solder flux for stainless steel, otherwise it won't hold long. In general, without the flux they lasted between 3-6k km which is not much. With flux it's solid!

[@markbutler9046]

@@FARANDFURTHER Did you use rosen core electronics solder? Or acid flux plumbing solder?

[@FARANDFURTHER]

@@markbutler9046 Originally I used only normal solder. But after reading up a bit I got flux (kind of acid) for stainless steel.

[@aaaarrrgggghh]

Drip feed engine oil onto your inner cable, it'll suck it in, use an oiler. When it gets out of the other side is done.

[@Moto-Rider22]

Hello .. What material is this Melted wire and where should I buy it? ( Link to any online store). The electric lead broke, it is soft... :)

[@FARANDFURTHER]

Hi, not sure what you mean? I'm using normal electrical solder (the thing used in electronics to connect parts). It is soft but it always was more then enough. If you asking about the cable itself its steel cable from DIY shops.

[@sythenalpha2037]

my clutch cable just snapped do you think this would work as a stop gap for about a week of riding if i follow the good comments: bike honda xl125 veradero.

[@FARANDFURTHER]

It has a potential to last much longer. My first repaired cable lasted 6000km! Just use good flux and cable and you should be fine!

[@markjenkins905]

My clutch cable has 100k km on it and looks new. Have you fitted an after market lever i.e it's rubbing against the cable ????

[@FARANDFURTHER]

Yes, it is usually after market levers which destroy the cable as the angles are not precise enough.

[@NoName-is6py]

I used second option and it worked.. Thank you..

[@FARANDFURTHER]

You're welcome! Glad it worked well.

[@WilliamJones-xh8xz]

Thanks for your good idea

[@FARANDFURTHER]

You are most welcome

[@CulichorHimself]

sooo clever and cool, Thank you Sr.

[@FARANDFURTHER]

Happy to help!

[@laceylace6662]

I have just brought that kit... and finally cut through the cable 😓 but the end has frayed..no matter how I try to cut it... so it cant thread.... how did you keep end tight together?

[@FARANDFURTHER]

Hi, cutting it tricky isn't it. I ended up the angle grinder with very thin plate. Or you need very good wire cutters - big one. It may help to pre-solder it in the spot where you're going to cut it and cut it soldered. That way it would keep together. For soldering you will need some strong flux for stainless steel otherwise solder won't stick, @Nightster recomended Bakers Floid No3, I use some random one from local manufacturer.

[@heliumigge8523]

I use a cablekutter to shave electrical wiers, works great

[@arunkrishnath2827]

great work

[@paulthompson8613]

Very cool fix

[@FARANDFURTHER]

Yep, it works just read some of the comments under the video, the guys have very good points. Especially using correct flux. I'm going to fix my Tenere clutch cable now I sourced one broken so lets see how that goes.

[@kiranpatil3262]

Very good job sir 👍👌

[@FARANDFURTHER]

Thank you.

[@kiranpatil3262]

@@FARANDFURTHER most welcome!!!

[@ftdesigns3356]

@@FARANDFURTHER powertillerclutch

[@joceliorodrigues1895]

Parabéns... Brasil.

[@FARANDFURTHER]

Hello to Brasil!

[@cartninja6479]

Emergency sure...

[@FARANDFURTHER]

Yep

[@bryanteko]

Perfect thanks will try that 💪💪

[@FARANDFURTHER]

Awesome, let me know how it went. Have the updated video as well.

[@EEEEMMMMKKKK]

Do I really hear a matrix printer in the background?

[@GeneralBW]

Hi, how has the throttle cable worked, has it held up?

[@FARANDFURTHER]

So the first cable I did using solder ends worked for about 6000km which was quite good. It failed because I didn't properly treated the end of the cable before soldering. Here in comments are very very good suggestions by @Luzianna Long and @Nightster how make this DIY rock solid! I tried later to use TIG welder to make the ends but that does not work because themperature makes the cable brittle, so solder is way to go and check the comments of those two, if you do it that way it will be forever.

[@jomiller2095]

why are you breaking so many cables? Just curious as I have never broken a cable in 35 years of riding.

[@FARANDFURTHER]

Hey Jo, I think the main reason would be using the after market levers. We are talking about 54000 km, every day riding but still, the cables snapped at the same spot every time. Which is at the lever right after the end. So I really think the levers are the cause of this.

[@jaysmith8162]

Huh

[@FARANDFURTHER]

🤔