Cables

July 17, 2015

Contents:    1. Service Info    2. Generic Cables    3. Inner Wires
4. AMF cables  5. Angel  6. Avanti  7. Batavus  8. Benelli  9. Cimatti
10. Columbia   11. Derbi   12. Garelli   13. General   14. Hercules
     ———————– < p a r t i t i o n > ————————-
15. Honda   16. Indian   17. Jawa   18. JC Penney   19. Kinetic  
20. Kreidler   21. KTM   22. Kynast   23. Lazer   24. Malaguti 
25. Minarelli  26. Morini  27. Motobecane  28. Murray  29. Peugeot
30. Puch  31. Rizzato  32. Sachs   33. Sears   34. Solex   35. Solo
36. Sparta   37. Tomos   38. Trac   39. Vespa 

 


1. Service Info

Welcome. This cable section is for control cables, that slide back and forth, not speedometer cables, that rotate. For speedometer cables, see Parts/Frame/Speedometer

Single or Double Ended: Some control cable inner wires have two ends, and some have only one. The “end” is a round piece if metal, usually soldered onto the braided steel wire. When a cable inner wire has only one end, it can be removed from the conduit (or sleeve or housing). When a cable inner wire has a ball of lead at both ends, then it is permanently trapped and cannot be removed without cutting one end off.

Tri-Flow lubricant

Tri-Flow

Oil can

Squeeze type oil can

3-in-one oil

3-in-1 oil

Lubing Cables: Old cables become sticky from deteriorated oil and corrosion. A few drops of fresh thin oil is often all the cable needs to work good again, after a long period of sitting. Apply a few drops of oil or synthetic lubricant (preferably Tri Flow) onto the upper exposed inner wire so that it runs downhill into the cable. The bike is leaned over so that cable entrance is going down. The oil takes a few minutes to flow down the wire. Straighten out any kinks in the cable. Also lube the throttle, especially sliding block kinds, and the levers, where the lever pivots, and where the cable pivots.

 

Cable cutter

Cable cutter

Cable end wires bent into an umbrella before soldering

End wires bent
into an umbrella
before soldering

Soldering iron

Soldering iron

Cutting cables: The preferred tool is called a diagonal cutting pliers. It must be fairly new and sharp to cut braided steel cable inner wires and coiled steel cable outer conduits. Most of the inexpensive kinds do not stay sharp long. 

Configuring cables: A single ended “universal” cable is configured, or made into, a double ended “specific” cable. Any cutting of the sleeve, adding stop pieces, adapters or adjusters is done first. Then the cable is installed on the bike. Lastly, the top end piece is installed in the correct location on the wire. The wire strands are bent into an umbrella, and soldered. This is often necessary when ready-made cables are not available.

 

 


2. Generic Cables

C1 front brake (most)

Rear Brake Cable

C2 rear brake (most)

C3 throttle cable (most)

C4 clutch (some)

C4 start/clutch (some)

 

 

 

 

 

 

 

 

 

FRONT BRAKE
sleeve x wire
upper end
lower end
REAR BRAKE
sleeve x wire
upper end
lower end
THROTTLE
sleeve x wire
upper end
lower end
START CABLE
sleeve x wire
upper end
lower end
CHOKE CABLE
sleeve x wire
upper end
lower end
Generic Cables
5mm black lined sleeve
6mm chrome end caps
39 x 48" Ø1.5
6mm pear
no end
C1 409600 $10
60 x 65" Ø1.5
6mm pear
no end
C2 14111 $10
37 x 47" Ø1.2
no end
3x5 inline
C3 409500 $12
43 x 51" Ø1.5
6mm pear
no end
C4 409800 $10
same as
throttle

 

 


3. Cable Inner Wires

WR1 brake wire

WT1 throt. wire

Cable Ends on Replacement Cables

Cable Ends on Replacement Cables

 

 

 

 

 

 

 

FRONT BRAKE
single ended
inner wire
REAR BRAKE
single ended
inner wire
THROTTLE
single ended
inner wire
CLUTCH
(START)

single ended
inner wire
DECOMP
(START)

single ended
inner wire
CHOKE
single ended
inner wire
Moped Inner Wires
(vintage European)
WF1 48" Ø1.5
6mm pear end
500000 $5
WR1 69" Ø1.5
6mm pear end
500100 $5
WT1 47" Ø1.2
3x5 inline end
409900 $5
WC1 67" Ø1.6
6mm pear end
14238 $5
WD1 40" Ø1.3
5x7 barrel end
decomp $8
same as
throttle
Long Wires
for high or wide bars
or modified frames
WFL 73" Ø1.5
6mm pear end
1456 $5
WRL 105" Ø1.5
6mm pear end
1410 $8
WTL 79" Ø1.3
3x5 inline end
1457a $8
same as
rear brake
WDL 79" Ø1.3
5x7 barrel end
1457b $10
same as
throttle
Thick Inner Wires WF2 49" Ø2.0
6mm pear end
thicker $8
WR2 65" Ø2.0
6mm pear end
thicker $12
none WC2 51" Ø2.0
6mm pear end
Vespa $5
none same as
throttle
Barrel Inner Wires WF8 49" Ø2.0
8x8 barrel end
thicker $10
WR8 65" Ø2.0
8x8 barrel end
thicker $12
WTP 47" Ø1.2
5x7 barrel end
Peugeot $8
WCS 48" Ø1.3
Ø5/6 barrel end
Sachs $17
Bicycle Inner Wires WF7 48" Ø1.5
7x7 barrel end
1456b $5
WR7 73" Ø1.5
7x7 barrel end
1456a $5
WTG 79" Ø1.3
4x5 inline end
1457 $5

 


4. AMF Cables

AMF brake arms

1978-83 AMF Roadmaster mopeds have special brake cables. All models, 110, 115, 120, 125, 130, 140, 141 have the same controls and hand brake levers. At the upper end the black plastic hand lever is a unique American design that requires a special cable end. The original end piece looks like a “T” but the replacement is just the top part of the “T”, made from a Ø3.9 x 7.2 mm brass cable end E5f, ground shorter to Ø3.9 x 5.9 mm.

On all models the lower end of the cable has no soldered-on cable end. The cable is the same but the piece that attaches it to the brake arm has two types. Models 110 and 115 have Hercules-Sachs type special clevis clamps (right in photo) on both front and rear. Models 120, 125, 130, 140, 141 have clevis clamp on front, and Grimeca pinch bolt (left in photo) on rear.

AMF Roadmaster front replacement brake cable, bare $19

 

AMF original brake lever and cable

 

 

AMF Roadmaster rear replacement brake cable, bare $19
pinch bolt $5, clevis clamp $15, adjuster $2, step ferrule $1

 

 

 

 

 

 

 

 

 


5. Angel/Speed Bird Cables

 

 

 


6. Avanti Cables 

 

 

 


70’s Magura controls

7. Batavus Cables

1970’s Batavus mopeds use 1970’s Magura controls. The left side is the rear brake and start lever. The right side is the front brake, throttle, and choke trigger. The brake cables connect to the levers with little adaptor pieces called socket bolts or cable anchors.

 

FRONT BRAKE
sleeve x wire
thickness
upper end
lower end
REAR BRAKE
sleeve x wire
thickness
upper end
lower end
THROTTLE
sleeve x wire
thickness
upper end
lower end
START CABLE
sleeve x wire
thickness
upper end
lower end
CHOKE CABLE
sleeve x wire
thickness
upper end
lower end
1976-78 Batavus HS50
top tank, low handlebars
M48 engine, bottom carb
33.5 x 37.2"
Ø1.5 wire
Ø6 pear
8x15 barrel
41-407 $15
57.5 x 60.8"
Ø1.5 wire
Ø6 pear
8x15 barrel
41-408 N/A
substitute $20
38.6 x 41.3"
Ø1.2 wire
5x7 barrel
3x5 inline
41-405 N/A
substitute $23
35.5 x 44"
Ø1.5 wire
no end
6mm pear
41-409 N/A
substitute $10
38.8 x 40.1"
Ø1.2 wire
5x7 barrel
3x5 inline
41-406 $15
1976-78 Batavus VA,
Starflite VA, Starflite HS
standard handlebars
M48 engine, bottom carb
37.0 x 40.7"
Ø1.5 wire
Ø6 pear
8x15 barrel
41-250 $20
61.0 x 64.3"
Ø1.5 wire
Ø6 pear
8x15 barrel
41-249 $33
substitute $20
41.6 x 44.3"
Ø1.2 wire
5x7 barrel
3x5 inline
41-248 N/A
substitute $23
39.5 x 48
Ø1.5 wire
no end
6mm pear
41-247 N/A
substitute $10
41.8 x 43.1"
Ø1.2 wire
5x7 barrel
3x5 inline
41-246 $13
1978-80 Batavus
Regency VA, Regency HS
std bars, spoke wheels
M56 engine, side carb
same as above same as above 38.5 x 41.2"
Ø1.2 wire
5x7 barrel
3x5 inline
41-434 N/A
Trac 84565 $19
same as above 41 x 42.5"
Ø1.2 wire
no end
3x5 inline
41-286 N/A
substitute $12
1978-80 Batavus
Regency VA, Regency HS
std bars, mag wheels
M56 engine, side carb
37.0 x 40.1"
Ø1.5 wire
Ø6 pear
Ø6 pear
41-397 $30
substitute $24
61.0 x 64.1"
Ø1.5 wire
Ø6 pear
Ø6 pear
41-398 $33
substitute $20
same as above same as above same as above

Note: 1976-77 Batavus Bronco has same cables as VA, but all are 10″ longer, because it has “ape hangars”.

 

Batavus throttle cable 41-248

41-248 and 41-405: These are very long throttle cables, for a moped, because the carburetor is below and behind the motor. They have a short Magura adjuster on top.

Substitute: The substitute cable has a different style of Magura adjuster at the top end.

 

 

Batavus choke cable 41-246

 

41-246 and 41-406: There is no adjuster on the choke cable. Instead there is a rubber boot (not shown) that keeps water and dirt from getting in.

 

 

 

Batavus start cable 41-247

41-247 and 41-409: These start cables are single ended, where the wire slides out, so the 5-8 step ferrule, and the Magura short adjuster are shown and sold separately. The upper inner wire end is held with a pinch bolt built into the black plastic Magura start lever. The adjuster is optional, since it is easy to adjust from the pinch screw.

 

 

Batavus front brake cable 41-250

41-250 and 41-407: These front brake cables have a 6mm 10-hex type adjuster on the bottom end, and a short Magura type adjuster on the top. The second adjuster on top is a convenience, so you can adjust it while riding.

Substitute: The substitute cable has no Magura adjuster at the top end.

 

 

Batavus rear brake cable 41-249

41-249 and 41-408: These rear brake cables have a 6mm 10-hex type adjuster on the bottom end, and a short Magura type adjuster on the top. The second adjuster on top is a convenience, so you can adjust it while riding.

Substitute: The substitute cable has no Magura adjuster at the top end.

 

 

batavus-regency-with-mags-front-brake-cable

Batavus front brake cable 41-397

41-397 and 41-398: These brake cables for mag wheel models have a “Ø6 pear” or “mushroom” on both ends, a 6mm 10-hex type bottom adjuster, and a short Magura type top adjuster. The top adjuster is a convenience, so you can adjust it while riding.

Substitute:  The substitute cable has no Magura adjuster. It has a similar but generic 6mm adjuster on the bottom end, at the wheel.

 

Batavus M56 throttle cable 41-434

41-434: It has a short Magura type adjuster on top.

Substitute: The 1981-84 Trac throttle cable is the substitute. It has a slightly different style of Magura adjuster. 

 

 

Batavus Regency choke cable

Batavus choke cable 41-286

41-286: This is a single ended cable. First the inner wire slides though a small brass choke plunger. Then a set screw holds it from the bottom end. Two tiny rubber o-rings go into grooves in the choke plunger. See Encarwi carburetors for that. At the top end, a 5 x 7mm pinch bolt, shown and sold separately, goes into a plastic thumb trigger in the right control. 

 

 


8. Benelli Cables 

 

 

 


9. Cimatti Cables

FRONT BRAKE
sleeve x wire
upper end
lower end
REAR BRAKE
sleeve x wire
upper end
lower end
THROTTLE
sleeve x wire
upper end
lower end
START CABLE
sleeve x wire
upper end
lower end
CHOKE CABLE
sleeve x wire
upper end
lower end
1977-80 Cimatti
City Bike
sliding block throttle
Minarelli V1, side carb
38 x 42" Ø1.5
6mm pear
no end
black $10
64 x 69" Ø1.5
6mm pear
no end
black $13
38 x 42" Ø1.2
no end
3x5 inline
black $12
43 x 47" Ø1.5
6mm pear
no end
black $10
none
1976-77 Cimatti
City Bike
wrap-around throttle
Minarelli V1, side carb
same as above same as above 38 x 42" Ø1.2
5x7 barrel
3x5 inline
black $20
same as above none

 

Cimatti early throttle cable, double ended

Cimatti early throttle cable, double ended, for the Cimatti elbow 2a
for the modern elbow 2g, exposed length is shorter, 3.5″

Domino "70s chrome" wrap-around throttle

“wrap-around” throttle

1976 and some 1977 Cimatti had Domino wrap-around type throttles and double ended throttle cables. 

 

 

Cimatti Carb Elbow correct

Cimatti Carb Elbow

Cimatti Carb Elbow shorter one

Carb Elbow shorter one

Dellorto carb elbows

 

 

 

 

 

 

Early type double ended cable: For the original double ended throttle cable to fit, the curved pipe aka carb elbow must be the one that is 22mm tall and 30mm long, at the far left. If a different carb elbow is used, then the cable must be cut and re-soldered to match.

5mm Adjusters: Wonder why a Cimatti early double ended throttle cable does not have the 5mm adjuster trapped onto the cable, but a Puch double ended throttle cable does? It is because the center hole is over 3mm on the Italian Dellorto M5-0.75 thread adjuster, but under 3mm on the German Bing M5-0.80 thread adjuster. So the 3mm diameter carb end passes through on Dellorto, but not on Bing.

 

Domino DA0 right control

“sliding block” throttle

Cimatti (most) throttle cable, single ended

Cimatti (most) throttle cable, single ended

1978 and later, and some 1977 Cimatti had Domino slide type throttles that used single ended throttle cables. The cable runs parallel to the handlebar.

 

 

Later type single ended cable: Most Cimatti are this later type. It does not care what carb or what elbow is on the other end. During installation the (usually new) wire is pulled almost taut, so any excess slack is removed. After the pinch bolt in the sliding block is tightened, the excess wire “tail” is cut off.

 

 


70’s Magura controls

10. Columbia Cables

Columbia Commuter mopeds and their alias names had two different frames, stamped sheet metal, or mono-tube, and two different engines, Sachs 505 or Solo. All Columbia models had front and rear hand brakes, with 1970’s Magura controls. The early 1977-78 sheet metal frame models with Sachs 505 engine, had single-ended (universal) brake cable wires, with Grimeca type pinch bolts on the lower end. But the tube frame models and the late 1979-on sheet frame models had special brake cable ends, shaped like an “S”. 

Columbia brake cable types

Left, American brake, original wire has an “S-end”
Right, Italian brake, wire has no end, held by pinch bolt

Columbia S-end brake with substitute cable

Columbia S-end brake with substitute cable

 

 

 

 

 

 

 

 

FRONT BRAKE
sleeve x wire
upper end
lower end
REAR BRAKE
sleeve x wire
upper end
lower end
THROTTLE
sleeve x wire
upper end
lower end
START CABLE
sleeve x wire
upper end
lower end
CHOKE CABLE
sleeve x wire
upper end
lower end
1976-78 Columbia
with Italian brakes
sheet metal frame
Sachs 505 engine
(short Bing carb elbow)
38.3 x 43" Ø1.5
6mm pear
no end
746-0289 $10
60.4 x 65" Ø1.5
6mm pear
no end
746-0290 $12
36.8 x 41.3" Ø1.2
5x7 barrel
3x5 inline
746-0291 $20
34+3 x 41" Ø1.5
no end
Ø5/6 barrel
746-0293 $25
37.4 x 39" Ø1.2
no end
3x5 inline
746-0292 $12
1978-80 Columbia
with American brakes
sheet metal frame
Sachs 505 engine
(long Bing carb elbow)
38.9 x 42.0" Ø1.5
6mm pear
"S" hook
746-0344 N/A
61.0 x 64.1" Ø1.5
6mm pear
"S" hook
746-0345 N/A
36.8 x 41.8" Ø1.2
5x7 barrel
3x5 inline
746-0291L $20
same same
1978-80 Columbia
with American brakes
tube frame, Solo engine
carb on bottom
same same 42.0 x 45.2" Ø1.2
5x7 barrel
3x5 inline
746-0347 $22
42.? x 50" Ø1.5
no end
6mm pear
746-0346 $12
42.? x 44.?" Ø1.2
5x7 barrel
3x5 inline
746-0348 $12

 

 

Columbia-Solo throttle cable

 

Solo engine Columbia: On Colombia with Solo engine, the throttle cable carburetor end passes through the a M6-0.75 thread adjuster on the top of the carburetor. So the adjuster is not part of the cable, unlike Puch, and like on the Colombia with Sachs engine.

 

Sachs Carb Elbows L long, R short

Sachs-Bing carb elbows
left is long, right is short

Sachs engine Columbia: On Columbia with Sachs engine, the throttle cable carburetor end passes through a M6-0.75 thread adjuster on the Bing carb elbow, so the adjuster is not trapped on the cable, and is sold separately. The carb elbow, aka curved pipe, can be either short or long. So there are two different throttle cables, short or long. The difference is 1/2 inch of exposed inner wire. 

Columbia-Sachs throttle cable (for short elbow)

 

This exposed length of 4.5 inches is for a “short” elbow. Removed, the short elbow total length is 2 inch with the adjuster, or 1 1/2″ without, measured with a curved wire through the middle.

Columbia-Sachs throttle cable (for long elbow)

 

There are some Colombia’s with “long” carb elbows. They need this cable with a 0.5″ longer exposed length. The long elbow, removed, has a total length of 2 1/2″ with the adjuster, or 2″ without.

 

Columbia Sachs choke cable

Columbia Sachs choke cable

 

See Hercules Sachs choke cable for info.

 

 

 

 


11. Derbi Cables 

 

 


12. Garelli Cables

 

FRONT BRAKE
sleeve x wire
upper end
lower end
REAR BRAKE
sleeve x wire
upper end
lower end
THROTTLE
sleeve x wire
upper end
lower end
START CABLE
sleeve x wire
upper end
lower end
CHOKE CABLE
sleeve x wire
upper end
lower end
1975-86 Garelli
horizontal cylinder
one speed models
with front facing carb
36 x 40" Ø1.5
6mm pear
no end
black $10
60 x 65" Ø1.5
6mm pear
no end
black $10
32 x 35" Ø1.2
no end
3x5 inline
black $12
see below none
1976-86 Garelli
vertical cylinder
two speed models
with side facing carb
same as above same as above 38 x 42" Ø1.2
no end
3x5 inline
black $12
see below none

 

Original Garelli Start Cables

Things that are shown removed from the cable are not included with the cable.

Things that are shown installed in the cable are included with the cable.

So on the first cable below, the step ferrule is part of the cable, but the adjuster and clamp bolt are not.

 

H. Horizontal cylinder engine (Eureka, Sport, Gran Sport, Rally Sport, Super Sport, others)

Garelli horizontal engine start cable versions

Eureka Flex Standard Ø1.5 start cable 503754.7300 N/A
front pull, cable stop on frame, requires clamp bolt in hand lever

 

 

 

 

 

 

Eureka Flex Deluxe Ø1.5 start cable 503501.7300  $17
front pull, cable stop on engine, requires clamp bolt in hand lever

 

 

 

 

 

 

Sport, Rally Sport, Gran Sport, Super Sport  506851.7300 $27
Ø1.5 front pull, stop on frame, requires adapter in hand lever

 

 

 

 

 

 

 

V. Vertical cylinder engine (Gulp Matic, VIP, VIP-N, Monza GT, Avanti and Cosmo remakes, others)

Garelli vertical engine start cable versions

Garelli Gulp original start cable, rear-pull 500201.7300 N/A
rear pull, cable stop on engine, requires clamp bolt in hand lever

 

 

 

 

 

 

 

Garelli VIP prototype cable, for sharp U-turn routing N/A
This sharp-bend U-turn shorter cable performed poorly.
The wide U-turn, longer cable was better, and superseded it.

 

 

 

 

 

 

 

Garelli VIP start cable for wide U-turn 507251.7300  $23
rear pull, cable stop on frame, requires clamp bolt in hand lever

 

 

 

 

 

 

 


Replacement Garelli Start Cables

12 Garelli replacement start cables are offered: 3 lengths H,G or V, 2 styles d or e, 2 thicknesses 1.5 or 2.0.

Length is the same as original. For shorter or taller handlebars, the cable length would be shorter or longer.

Thickness is the same as original. (in mm) wire 1.5, conduit 5. HD cables are thicker, wire 2.0, conduit 6.

Why so many? 1) Garelli mopeds have different engines. The type of Garelli engine Horizontal, Gulp, or VIP, and the cable routing, determines the cable length. See above photos of original cable routing. 2) Garelli mopeds can have 2 different hand lever cable end pieces. The type of end piece in the hand lever (adapter “d” or clamp “e“) determines the style of cable inner wire end (mushroom or sideways barrel).  3) Standard “std” 1.5 mm, or heavy duty “HD” 2.0 mm thicknesses are offered. The thickness is a matter of choice.

Why heavy duty? Often the starter mechanism inside the engine gets worn, glazed or messed up, causing the starting clutch to slip. Then the start lever has to be squeezed real hard. A thicker cable performs better when the lever is squeezed really hard. The thicker HD cables are for Garelli mopeds that slip when starting.  

 

H. Horizontal cylinder engine (Eureka, Sport, Gran Sport, Rally Sport, Super Sport, others)

H1.5d start cable std bare $10  for when clamp “e” is missing
H2.0d start cable HD bare $20  for when clamp “e” is missing
H1.5e start cable std bare $10  for when clamp “e” is present
H2.0e start cable HD bare $20  for when clamp “e” is present

These “H” start cables are front-pull. So they are the shortest. See horizontal engine start cable photos above.

The replacement cable bare is just the wire and the conduit-with-end-caps. The pieces a, b, c, d, e are sold separately. They slide off or detach from the single-ended cable. See below.

 

 

 

 

 

 

G. Vertical cylinder “early” engine (Gulp Matic, others)

G1.5d start cable std bare $10  for when clamp “e” is missing
G2.0d start cable HD bare $20  for when clamp “e” is missing
G1.5e start cable std bare $10  for when clamp “e” is present
G2.0e start cable HD bare $20  for when clamp “e” is present

These “G” start cables are rear pull. So they are longer than “H”. They do a quick sharp U-turn, and stay on the same side of the frame. So they are not as long as the “V” type.

The replacement cable bare is just the wire and the conduit-with-end-caps. The pieces a, b, c, d, e are sold separately. They slide off or detach from the single-ended cable. See below.

 

 

 

 

 

 

V. Vertical cylinder “late” engine (VIP, VIP-N, Monza GT, Avanti and Cosmo remakes, others)

V1.5d start cable std bare $10  for when clamp “e” is missing
V2.0d start cable HD bare $20  for when clamp “e” is missing
V1.5e start cable std bare $10  for when clamp “e” is present
V2.0e start cable HD bare $20  for when clamp “e” is present

These “V” cables are rear-pull. They are the longest, because they go to the rear first, then make a wide U-turn behind the engine to the other side of the frame.

The replacement cable bare is just the wire and the conduit-with-end-caps. The pieces a, b, c, d, e are sold separately. They slide off or detach from the single-ended cable. See below.

 

 

 

 

 

 


Garelli Start Cable Pieces

a. clamp (pinch bolt) $$4  short for engine lever xxxx xxxx substitute, good quality, good design

b. ferrule (cable stop) x N/A  4.7 to 7.5 by 11.3, 6.1 id xxxxx Garelli original
b. ferrule (cable stop) x $$3  3.8 to 7.0 by 10.8, 5.9 id xxxx xsubstitute F2 Motobecane 16944

c. adjuster (cable stop)  $$6  M6 thread, ribbed xxxx xxxxxx  Garelli original 000315.9522
c. adjuster (cable stop)  $$2  M6 thread, hex style xxxx xxxx  substitute

d. adapter (socket bolt) $$4  cable anchor long with washer x substitute, washer keeps cable centered
d. adapter (socket bolt)  N/A  cable anchor short
 70’s Domino Garelli original 506851.5178, for start lever, pre-1986
d. adapter (socket bolt)  $$4  cable anchor 80’s Domino xxxx for all-black Domino controls, 1986-on Garelli models

e. clamp (pinch bolt) xx N/A  long for hand lever xxxx xxxxxx Garelli original 0009504.4554
f. clamp (pinch bolt) xx $$4  long for hand lever xxxx xxxxxx substitute, requires internal washers to stay centered
f. clamp (pinch bolt) xx $$4  long for hand lever xxxx xxxxxx this is difficult to install, more about this later…

 

Garelli start-clutch cables have been a difficult subject at Myrons Mopeds for many years. Not only are there different cables, engines and routings, but the bikes can have different end pieces, clamp “e” or adapter “d”. Those things can be changed, so the customer has to say what kind the bike has. To make matters worse, the clamp “e” has been scarce and unavailable since the 1980’s. So there is a lot of explaining to do. And then, there is a tendency for the start cable to wear out or break, because the starting clutch mechanism inside the engine slips, which requires the cable to be pulled very hard. 

 

Garelli start lever without socket bolt. 8mm hole size is same as brake but lever is thinner.

Garelli start lever
without socket bolt.
8mm hole size is
same as brake but
lever is thinner.

Domino Socket Bolts

Domino Socket Bolts

Domino Socket Bolts: 1970’s Italian moped brake levers and start lever use these adapter pieces to convert the pear end to a longer sideways barrel. They are more than just an adapter, because they have a slot for the inner wire to pass through, to allow installation. There are two lengths, 16mm for brake levers, and 14mm for decomp/start levers. It is important to have the cable wire centered in the lever. So there is a groove that the sheet metal lever sits in when the lever is squeezed. That groove keeps the socket bolt from sliding sideways. Without that groove, the cable still functions, but maybe not as well, or it might make a “click” sound and feel, when it does not stay centered. A longer one will substitute for a short one, with a 8mm washer under it. But the washer covers the centering groove, so it might not perform as well as an original.  

 

 


13. General Cables 

 

 

 


70’s Magura controls

14. Hercules Cables

Hercules mopeds are commonly known as Sachs in the USA. We use the true maker name to avoid confusion with Sachs engines, which are used on non-Sachs bikes, like Sparta, General, KTM, and also to include the alias brand names Eagle, Pegasus, etc, made by Hercules. 

FRONT BRAKE
sleeve x wire
upper end
lower end
REAR BRAKE
sleeve x wire
upper end
lower end
THROTTLE
sleeve x wire
upper end
lower end
START CABLE
sleeve x wire
upper end
lower end
CHOKE CABLE
sleeve x wire
upper end
lower end
1975-76 Hercules Sachs
M1, M2, P1
sheet metal frame
Sachs 504 (long elbow)
36 x 40" Ø2.0
6mm pear
no end
1707073 $18
with Ø1.5 $12
62 x 66" Ø2.0
6mm pear
no end
1707076 $20
with Ø1.5 $12
35 x 40" Ø1.2
no end
3x5 inline
1707292 $12
32+3 x 39" Ø1.5
no end
Ø4/6 barrel
1707381 $25
37 x 39" Ø1.2
no end
3x5 inline
1708003 $12
1975-76 Hercules Sachs
M4, M5, P3
tube frame models
Sachs 505 (long elbow)
same as above none
(foot brake)
same as above same as above 37 x 39" Ø1.2
no end
3x5 inline
1707291 $12
1977-83 Hercules Sachs
Westlake, Sundancer
sheet metal frame
Sachs 504 (long elbow)
36 x 40" Ø2.0
6mm pear
6mm pear
1707005 $35
with Ø1.5 $22
62 x 66" Ø2.0
6mm pear
6mm pear
1707001 $38
with Ø1.5 $22
35 x 40" Ø1.2
no end
3x5 inline
1707217 $12
same as above 37 x 39" Ø1.2
no end
3x5 inline
1708009 $12
1977-83 Hercules Sachs
Balboa, Suburban, Prima
tube frame, foot brake
Sachs 505 (long elbow)
same as above none
(foot brake)
same as above same as above same as above
1980-83 Hercules Sachs
Seville (oil injection)
sheet metal frame
Sachs 505 (long elbow)
?? x ??" Ø2.0
6mm pear
6mm pear
1707003 N/A
none
(foot brake)
same as above same as above same as above
1980-83 Hercules Sachs
Prima G3 (top tank)
tube frame, lower bars
Sachs 505 (long elbow)
32 x 36" Ø2.0
6mm pear
6mm pear
1707099 $30
none
(foot brake)
31 x 36" Ø1.2
no end
3x5 inline
1707216 $12
28+3 x 35" Ø1.5
no end
Ø4/6 barrel
1706902 $25
33 x 35" Ø1.2
no end
3x5 inline
1708008 $12

 

Grimeca Brake Arms

Brake cable lower end types
1. built-in clevis for 6mm pear end
2. Grimeca pinch bolt for no end
3. Tomos pinch bolt for no end
4. 8mm barrel end or pinch bolt
5. clevis end or clevis pinch bolt

Before 1977 Hercules front brake cable, single ended

Before 1977 Hercules front brake cable, single ended

 

 

 

 

 

Early Hercules cables were all single ended, in the tradition of bicycles. The brake cables had clevis type pinch bolt ends, type 5 at the right. The clevis piece and adjuster are sold separately.

Hercules front brake cable, double ended

After 1976 Hercules front brake cable, double ended

 

 

 

 

 

Hercules cable end clevis type

Hercules clevis end
is riveted to arm

 

Later Hercules had double ended brake cables, in the tradition of motorcycles. They attached easily and securely to a clevis piece that was riveted to the lever arm. This made it safer and more fool proof, but also made the brake cables specific and difficult to get or make.

The early controls (not shown), here nicknamed “Early 1970’s Magura” had bottomless threaded holes, requiring standard M6-1.0 adjusters. After 1976-77 they had the “1970’s Magura” controls. The brake cable end holes changed from threaded bottomless to slotted with bottom, to accept either a plain cable or, optionally, a Magura type adjuster.

 

Hercules Sachs choke cable

Hercules Sachs choke cable, single ended

Sachs air filter with choke

Sachs air filter

Front half with choke

Front half w/choke

 

 

 

 

 

The Sachs external choke is part of the air filter box, front half. The Ø3 end goes in the plastic slide. The upper bare end requires a 5×7 pinch bolt for the right thumb lever. The design requires that the upper end of the cable be removed to install or remove the cable. (If there was a double ended Sachs choke cable it would require a Magura type adjuster to be adjusted way up/tighter to allow for installation slack). 

Hercules Sachs Throttle Cable

Hercules-Sachs throttle cable, single ended

Since this is a single ended cable, it does not matter if the carb elbow is long or short. The pinch bolt can be located accordingly.

All original Hercules cables had light grey plastic oil ports, located a few inches from the top end. Replacement cables do not have oil ports. 

 

 

Find out more about the Cables »