Replacing throttle / choke cables

[tunnelrider]

Hello all,

I've got new control cables to install.  Eagerly anticipating an easy job (1st mistake) taking the old ones off I've come into difficulty with the throttle cable adjuster / splitter unit.  The unit has a screw end for the twin cables to the carbs which comes off easy enough but there isn't enough length in the handlebar cable to withdraw the piece which all the cables attach to.  Therefore I can't detach either the carb cables or the handlebar cable.
See below for the photos - the piece which holds all the cables is withdrawn to it's max. extent.  The bright spot in the middle of the piece is the end crimp of the handlebar cable.  There is no way of further disassembling the adjuster unit that I can see.

Has anyone had success replacing their control cables using these adjuster units before or will I have to use the old cables while I (dammit) order new adjuster units?
Cheers

[Ed Miller]

If you push those cables into that plug, can't you move them sideways a little and pull them all the way out a larger hole?  You'll have to hang on to the internal part to stop it from sliding back in, not the outer housing like it shows in your second picture.

It's been a blissfully long time since I've done that job.  Which probably means I'm due.  But it can be done.  I do remember that I don't like it.

[Bob_Roller]

What year bike is it

When I replaced the cables on my '81 R65, had no issues with getting the cables out of the ' splitter ' .

But on the '82 LS, I had the same issue that you have .

Can't remember what I did to get by this, did this 5 years ago .

The best I can remember, I used very small needle files and removed some plastic from the part that the cables go into .

I'm thinking I did this to the slot that the single cable from the handlebar goes into the part .

I'm not taking it apart right now, still 105 F  in the garage .

[tunnelrider]

Thanks for your replies so far Ed and Bob,

It's a 1985 R65.  I'll try your suggestions.  A strand on the right side carb cable has now unraveled at the splitter and is now totally useless, so I'm willing to get more experimental!  I'm really tempted to just cut the handlebar cable to withdraw the whole lot, since I have a new replacement.  Only thing is I can picture the same problem on installing the new one, so yeah, filing the length down of the outer unit may be a way around it.
Cheers

[tunnelrider]

Ha ha well my patience got the better of me and I cut the handlebar cable, withdrew the lot and set about fitting the new cables.  All was going ok until I broke off a side of the inside piece trying to wedge it open to slide the new handlebar cable in.  Still had the problem of not enough length.  I'll have to wait for a replacement inside piece,  hopefully it's not as brittle as a 30yr old piece of plastic.  Man this ain't easy!

[Barry]

I Know this is no help but the earlier twin cables all the way from throttle to carb are a piece of cake by comparison. I guess you couldn't adopt that approach without a new twist grip housing.

[Mike V]

Hopefully this will help.  I might suggest after cleaning to reassemble dry.  It's a bit finicky.  If I remember correctly; you'll have to slacken the single cable free length to pull the splitter out with the twin cables, then the cables can be removed from the splitter.  ??  My only problem with the splitter setup on my 81 was the lack of adjustment on the single cable entry.  It's operated flawlessly since the pictures were taken.  Report back when you can.

Thought I had some better pictures.

[RandyN]

I haven't had the cable apart on my 86 yet, but on my 76 Bonneville  I had to pull the twist grip apart at the handle bar. That allowed me to disconnect at the handlebar end and create enough slack at the splitter. You do need to get the get the splitter assembly out of the housing to properly take the carb cables off.
Hope this makes sense and helps
Randy

[tunnelrider]

Thanks a lot guys for your input and information on this. I wanted to crack on with the job so I scavenged the inside piece of the choke splitter.  There was good free length on the choke splitter like in your photos Mike.

To get more workable area on the throttle splitter I cut off the thinner threaded end of the splitter housing that the single cable adjuster screws into, which gave me an extra ~1 inch of maneuverability, what a relief (thanks for the idea Bob!). The metal adjuster still screws in on a few threads. Maybe a risk to have this permanently, but feels solid and it's got the lock nut to support it.

After fiddling around with fitting the cables I can see how it (might) be done with the original length of the adjuster and it's probably like what Ed says... you have to push all the cables past the inside piece before seating any of the crimps.  If taking apart, start with the handlebar cable,  hold the end crimp and push the inside piece away, you might be able to work the cable out.  Installing cables, maybe fit the carb cables first but don't seat the crimps then work the handle bar cable through. Is bloody fiddly though, what a laugh.
Cheers.
PS when the new splitter arrives I'll probably re do it, but I'll cover the wire cables when holding them with pliers to avoid wearing them out.

[Bob_Roller]

I looked in my  maintenance records for for my bikes, on the work that I have done and found what I did to my '82 LS to solve this problem .

I opened up the slot at the very end of the plastic splitter, where the single cable from the handlebar sits .

I removed just enough material from the slot at the very end, that the swaged cable end will come out the side, instead of pushing it out of the splitter all the way.

Hope this will help someone with this problem later on !!!!!

[donbmw]

A couple months ago I replace my cables. You need to remove the cable assemble from the bike and the spliter will come apart with out any problems this gives you alot of slack.

[Runninn1]

Recently did the same replacement on my 86 R65. I too pulled the rascal off the bike and worked on it on a workbench. Next time maybe I will remember....in 2020....

[davidpdx]

Did this job this summer. Had a heck of a time getting it back together and came to the conclusion that an extra set of hands made all the difference in the world when reinstalling. Three cables to hold in place at the same time equals three hands to hold them tight. Good luck and a little malt flavored lubricant helps as well.  

[tunnelrider]

Ha ha oh yeah that malt flavoured lubricant, can't do without that.  I seem to have a steady stream of it arriving then leaving rapidly.  Thanks for all your help, still waiting for the new splitter to arrive.  Bob I can see how your tip would work, it may work for installing the single cable too.
When I first started I tried straightening the cable as suggested but it didn't increase the length of slack by anything really.