Throttle and Shift Tube

Throttle and Shift Tube

In this specific case we were lacking the throttle and shift cable pulley including all washers clips. The newly ordered spare parts were unfortunately of such bad quality and accuracy that some extra rework was required.

The pictures illustrate the assembly order and the position of each part. Pay attention to the correct position of the throttle and shift pulley! Make sure all contact points of washers, pulleys and tubes are well lubricated to secure a smooth operation.

Cable Alignment

Cable Alignment

In order to prepare all cables for the correct alignment inside the headset it is of paramount importance to make sure that they are correctly positioned at the exit around the stearing column.

cable end cap Inside the headset there is cable bracket that holds the cable end and guides the wire. The round headset is equipped with a metal bracket that requires some specific housing end caps (top hat) to properly position and align the cable to the bracket. Some cable sets do not contain such end cabs and you have to add them additionally.

We use a little trick when it comes to the cap end of the throttle cable. Most throttle cables have a small end pin soldered to the side that connects to the carb. This tiny pin of course prevents you from pulling out the wire and consequently no end cab can be attached. The trick is to simply to create a small cut just big enough for the wire to get through. Like that you can now push the end cap upon the cable.

install Headset

Pictures soon to come...

install Headset

Simultaniously guide the cables and the loom through the headset. Already now secure the approximate end position/direction of the cables. Now insert the headset screw and softly tighten it while holding the squared nut in its target position.

Install Front Brake Cable

Front Brake Cable

Guide the cable through the headset and into the throttle tube. You may need to bend the cable in order to get it through the hole of the headset. The throttle tube contains two notches opposite to each other but slightly offset. The cable has to go through both holes and end up at the bar where to lever is mounted.

The front brake cable has to have an end cap that connects into the hole inside the lever bracket. Make sure the end cap is properly inserted.

Install Clutch Cable

Use front brake cable pictures as reference

Clutch Cable

The same installation process applies to the clutch cable as for the front brake cable. The only difference is that the clutch cable doesn't have a dedicated end cap like the front brake cable does. Furthermore the clutch cable has to be installed without the inner cable. There is simply not enough space for the soldered end nipple of the inner cable to insert both at the same time.

Install Cable Loom

Cable Loom

Use the same hole as for the front brake cable to thread the loom through the headset. Guide it along the throttle tube to the hole behind the switch assembly compartment. Unfortunately the cable lenght is rather short, hence make sure that the loom is properly set all the way.

Inner Cable Connection

Inner Cable Connection

As soon as all outer cables have been correctly installed you can now mount the metal bracket inside the headset. Thread in the respective end caps and insert the end nippels into the shift and throttle pulley. It is just fair to say that it unfortunatly sounds much easier and faster done as it is in reality. Be ready to show some patience.

Finally adjust the headset in line with the front wheel and fully tighten up the headset screw (wrench size 13).