Frustrating task

[Dizerens5]

There are quite a few jobs to do on an old R65, some of them not too easy. But I nominate for the most infuriating, most frustrating and most likely to turn a quite kind-hearted Sunday mechanic into a mad serial killer -- fitting new throttle cables into the twistgrip and ( if you have the low European handlebar) even just getting them there in the first place. What sadist invented this crazy arrangement? There are far better layouts to use.

[Bob_Roller]

Is this the dual cable set up at the hand grip on the '78-'80 year bikes ?

[Barry]

If you do mean the individual separate cables from twist grip to carb I agree it's more than a bit fiddly to connect both ends at the twist grip. I'm trying to remember how I do it. Keep some tension on the outers and slap the top plate on quick I think.  Its never a first time affair though.

To add more frustration how do you figure out which cable goes to the top left or right carb ?  I think left but not sure it matters other than it might give the smoothest cable run.


When all said and done I don't think I'd prefer the other option with a splitter box under the tank. It can only add tighter bends and more friction.

[Dizerens5]

yes Bob it's the dual cable setup. It becomes very slightly easier if cables are not connected to the carbs or if they are already, then if you take out the adjuster on the carbs so the cables are slack. As for the low European handlebar I thought (JUST in time) of tying a length of locking wire to the top end of each cable, pulling it out and then using the same wire to pull the new cable through the stuff under the tacho etc., it got it routed right. Top cable goes to left carb on my R65 it seems ok.

[nhmaf]

FWIW, the splitters under the tank can have their own special brand of 'joy'.    
The best/only way to cope is to disconnect them at the carb end so you're not pulling against the carb springs while trying to fit the other ends in.

[Rob Valdez 79 R65]

I have a '79 with double cables.

I get the bottom nipple in place on the puller, and then the top.
Then I put the narrow end of the cap in place to capture the top nipple, and pull it backward (toward the grip) until it drops in place.

edit: I'm not sure, but I think I have to grasp both cables with thumb & forefinger, and pull the sheaths back at the same time.  This has the added advantage of putting tension on the inner cables and keeping the nipples in place.

I'll admit it took a few times before it became easy, but that was so long ago...




I find this procedure about 1000% easier than the drive shaft boot installation.

[montmil]

...I find this procedure about 1000% easier than the drive shaft boot installation.

I'm thinking of a sorta off topic list kinda like "Simple Sounding Airhead Service Chores That Turn You Into an Axe Murderer."

That blankity-blankity-blank drive shaft boot would make the top three for sure.

Monte

[Dizerens5]

Don't forget getting the left air filter cover off! Breather hose cements it firmly in place....I still haven't beaten that one. Some day I will.

[Rob Valdez 79 R65]

Don't forget getting the left air filter cover off! Breather hose cements it firmly in place....I still haven't beaten that one. Some day I will.

I typically take a small screwdriver, after removing the clamps, and push it up under the bottom of the hose, and run it around the perimeter as far as I can.  That breaks any "stickiness" free, allowing me to work the hose down on the intake horn as far as it will go.  With the other hose clamps loose, I can usually get the horn off easily, and then the left air filter cover is free.

I got rid of the choke lever a long time ago.  I have had it mounted on the handlebar a la '81-on, but my next incarnation will have simple rods attached to the choke levers on the carbs.
With that out of the way, there is not much in the way of the air box.

[Dizerens5]

Thanks Rob!

[Rob Valdez 79 R65]

And to get the long through-screw to meet it's destination easily, I peek through the left-side snorkel hole, where I can see what is going on inside.