Hand Throttle Controller

[rwmann]

Thanks.

Old cable and housing had been cut in the late 1970s, but was useful and measurable. Planning to bore out the plunger to re-set and re-crimp the new cable.

You’re right that full range for the hand throttle is just a nudge of the foot throttle range, especially with the Solexes.

[mraitch]

Emmy was able to 'open up' the crimp, remove cable we then recrimped the 'crimp'. I imagine a bit of soldering might help, but unless you have might powerful springs on your carbs, not a LOT of pull force required.

[Lorna c]

did anyone just spray WD40 down inside the sleeve to loosen it up ? just curious.

[redroadster]

Its a manual fast idle
As a auto one would be too complicated

[Lorna c]

awah

[rwmann]

Got a 12" section of .188" (3/16") diameter, .049" heavy wall aluminum tube, cut to +/- 3.25" original plunger length, filed one edge flat to match the flat on the plunger, drilled through and tapped the tube for the knob hold-on screw, plus one more of the same to crimp the replacement inner cable, threaded the inner cable through the new plunger, installed the plunger in the controller body, crimped the inner cable in place with the new hold-down screw, trimmed inner cable to length, and voila!

[greydog]

What will you use for the bell end?
Dan

[rwmann]

Used a 1.5mm Teflon coated brake cable with Shimano bell end, and back-threaded it through the top recess of the throttle arm, through the outer cable cover end, out to and through the controller body. The bell end seats nicely in top recess of the throttle arm, and the 1.5mm is an apparently perfect fit into the outer cover. Very low friction.

[Lorna c]

dont they make solderable tips somewhere ?? dang if they'd hold I choose fishing weights .. haha but those tips always hold me back . r there tips that u can just weld or solder to ends ? shrinktubing dont work well either . a knot isnt always big enough and looks terrible . .

[rwmann]

Indeed, there are fusibles (soldered, electrically or laser welded), side-clamp, and end-clamp cable stops. The side-clamps are traditional, but usually result in the cable fraying, which is not a factor with the fusibles and end-clamps.

[Lorna c]

Indeed, there are fusibles (soldered, electrically or laser welded), side-clamp, and end-clamp cable stops. The side-clamps are traditional, but usually result in the cable fraying, which is not a factor with the fusibles and end-clamps.

thank u

[mraitch]

emmy drilled a small divot with a drill - melted the end of a standard bike cable and stuck the throttle cable end in until it cooled - voila - she's smart that way.

[spl310]

https://www.zoro.com/buyers-products-th ... cyEALw_wcB

[Ausdat]

Can someone explain how to open up the original crimp between the cable and the plunger.