CONTENTS: Welcome 1 One-Ended Cables 2 Cable Parts 3 Two-Ended Cables < grey = planned
Welcome. This cable section is for control cables, that slide back and forth, not speedometer cables, that rotate. For speedometer cables, see Frame Parts/Speedometer.
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 sleeve. 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.
Universal cables only have one “end”. A pinch bolt is placed anywhere along the wire, where ever is correct for that application. Once the pinch bolt is tightened and soldered, the cable is no longer universal. It is specific for that machine and others like it.
There are end pieces that can be purchased separately to “configure” a universal cable, for some mopeds. Some of those pieces, in some cases, must come from the old cable. For example, a Peugeot 103 throttle wire equals a universal throttle wire plus a 5 x 7mm “sideways barrel” end adaptor. Once the pictures and diagrams are all displayed, the most common cable configurations and their applications will be listed.
There are many more cables. Too many. More talk and diagrams are being planned…
1 O N E – E N D E D C A B L E S
==============================================================================
Row C = Cables
Row W = Wires
| Part # | # | ←picture#………Description | Price | Applications |
| ###### | ### | ############################# | #### | ################################# |
| …………C…A…B…L…E…S………… | speedo cables are with speedometers | |||
| 409600 | C1 | cable F brake univ 39″sleeve 48″wire | $12 | nylon-lined low friction high quality |
| 409700 | C2 | cable R brake univ 62″sleeve 69″wire | $12 | nylon-lined low friction high quality |
| 409800 | cable clutch univ 43″sleeve 51″wire | $12 | nylon-lined low friction high quality | |
| 409500 | C3 | cable throttle univ 37″sleeve 47″wire | $12 | nylon-lined low friction high quality |
| 1438 | cable bicycle gear shift | $6 | not high quality but not bad | |
| 14111 | cable bicycle brake | $6 | not high quality but not bad | |
| ………I…N…N…E…R……W…I…R…E…S……… | ||||
| 1456 | cable wire bicycle brake1.5×1850=73″ | $3 | many Applications all mopeds DIY | |
| 14238 | cable wire bicycle brake1.6×1700=67″ | $3 | many Applications all mopeds DIY | |
| cable wire Peugeot throttle | $7 | Peugeot 102 and 103 | ||
| 1457 | cable wire bicycle gear shift | $3 | when grinded makes longer throttle wire | |
| 409900 | W2 | cable wire throttle flexible | $5 | for making/repairing most throttle cables |
| 500000 | cable wire front brake 48″ | $6 | many Applications all mopeds DIY | |
| 500100 | W1 | cable wire rear brake 69″ | $6 | many Applications all mopeds DIY |
2 C A B L E P A R T S
==============================================================================
P1
P2 a,b,c
P3 a,b,c
P4 a,b
P5
P6 a,b,c
P7 a,b,c
P8 a,b
| Part # | # | ←picture#………Description | Price | Applications |
| ###### | ### | ############################# | #### | ################################# |
| 490500 | P1 | barrel pinch bolt D=5.5 L=7.3 | $2 | for making/repairing any throttle cable |
| P2a | barrel pinch bolt D=6 L=14? 6hex/7sqr | $3 | Motobecane brakes | |
| P2b | barrel pinch bolt D=6 L=6? | N/A | narrow throttle, must grind a P1 | |
| P2c | barrel pinch bolt D=7 L=12? 6hex | $4 | Peugeot choke & throttle | |
| P3a | barrel pinch bolt D=8 L=16? 8/8hex | $5 | Peugeot brakes | |
| Vespa | P3b | barrel pinch bolt D=7 L=15? 8/7hex | $5 | pinches good and resists cutting |
| P3c | barrel pinch bolt D=8 L=10? | $2 | must grind bolt end into dome | |
| P3c | barrel pinch bolt D=8 L=10? | $4 | after grinding: doesn’t slip or cut wires | |
| P4a | barrel pinch bolt D=8 L=16? thick wire | $3 | extra thick | |
| P4b | barrel pinch bolt D=8 L=20? thin wire | $3 | ||
| H60 | P5 | Grimeca pinch bolt, brake at wheel | $6 | almost all Italian and many others |
| P6a | clevis pinch bolt | $6 | Sachs, KTM | |
| P6b | clevis pinch bolt | $6 | Sachs, KTM | |
| P6c | clevis adaptor | $4 | adapts a pear end to clevis | |
| P7a | Bicycle pinch bolt, brake at wheel | $2 | like Grimeca P5 but smaller M5 not M6 | |
| P7b | cable wire end cap – crimp-on | $1 | keeps frayed wires from poking out | |
| P7c | bicycle brake cable ferrule | $1 | stops the sleeve from slipping into hole | |
| Peugeot | cable pinch bolt Peugeot decomp | $3 | stepped pinch bolt Peugeot decomp | |
| M9 | cable pinch bolt 8x14mm start lever | N/A | maybe use Magura one | |
| Tomos | loop pinch bolt 6-pieces M6 Tomos | $7 | Tomos 1976-91, lever has 10mm hole | |
| Vespa | loop pinch bolt 6-pieces m7 Vespa | $7 | Vespa mopeds, lever has 11mm arch |
E1 a,b,c,d,e
E2 a,b
E3
E4
| Part # | # | ←picture#………Description | Price | Applications |
| ###### | ### | ############################# | #### | ################################# |
| 25880 | E1a | cable end D=8.1 L=8.1 pear adapter | $2 | adapts a pear end to a barrel end |
| 25349 | E1b | cable end D=6.0 L=7.0 wire=1.2 | $2 | solder end for throttle wires |
| E1b | continued … | also adapts a carb end to a throttle end | ||
| Sachs | E1c | cable end D=4/6 L=12? adapter | $8 | Sachs start cable |
| Barnett | E1d | cable end D=5.0 L=8.0 adapter | $4 | adapts a carb end to a throttle end |
| 25362 | E1e | cable end D=6.0 L=7.0 wire=1.6 | $2 | solder end for small lever brake wires |
| E2a | threaded rod nut M6 | $1 | many Asian brakes are “rod” type: | |
| E2b | threaded rod barrel | $4 | a threaded rod is the end of the wire | |
| E3 | elbow 45 deg | $6 | Delorto & others | |
| E4 | inline oiler | $4 | for putting oil into the cable | |
| none | cable end cap “ferrule” 5mm | $1 |
A1
A2
A3
A4
A5 a,b
A6
A7 a,b,c
A8
A9
A
| Part # | # | ←picture#………Description | Price | Applications |
| ###### | ### | ############################# | #### | ################################# |
| 219625 | A1 | cable adjuster M5x0.75 w/nut | $9 | for Dellorto (finer thread) carb elbow |
| 219626 | A1 | continued … | equals Tomos 219625 plus 219626 | |
| A1 | cable adjuster M5x0.80 w/nut | $4 | for Puch (Bing) carb elbow | |
| A1 | cable adjuster M5x0.90 w/nut | $5 | for Motobecane? | |
| A1 | cable adjuster M5x1.00 w/nut | $2 | coarser – not for any moped cable thread | |
| M6adj | A2 | cable adjuster M6x1.00 hex no slot | $1 | the most common cable “stop” |
| A3 | cable adjuster M6x1.00 round | $4 | ||
| A4 | cable adjuster M6x1.00 hex long used | $5 | Puch wheels and others | |
| A5a | cable adjuster M7x1.00 round slotted | $5 | ||
| A5b | cable adjuster M7x1.00 hex used | $5 | ||
| A6 | cable adjuster M8x1.25 round slotted | $5 | ||
| A7a | thin nut for adjuster | $1 | ||
| A7b | thin nut for adjuster | $1 | ||
| A7c | thin nut for adjuster | $1 | ||
| A8 | inline cable adjuster | $5 | custom | |
| A9 | Magura cable adjuster good used | $7 | only comes on new Puch brake cables | |
| 222592 | cable adjuster M6x1.00 round slotted | $4 | Tomos 1992-2008 and others | |
| cable adjuster 1/4-24? hex aluminum | $5 |
3 T W O – E N D E D C A B L E S
==============================================================================
Left, the two versions of the Puch double-ended throttle cable. Left cable is the “Free Spirit” kind, for the tube frame bikes like Sears Free Spirit, Murray, JC Penney Pinto, and Puch Magnum. These models have a short carb elbow because the frame is lower there. The shorter elbow requires the shorter cable exposed length. Price is $13.00
Right cable is the “Puch Maxi” kind, for sheet metal frame Puchs with the long carb elbow shown. Price is $20. It has about 12mm more exposed wire length, as you can see. The ones sold elsewhere on the internet for “Puch” are the “Free Spirit” kind. Their inner wires are too short and cannot idle down when installed on a stock Puch Maxi.
Garelli Start/Clutch Cable
The Garelli double ended starter cable is tricky.
Garelli start lever
without socket bolt.
8mm hole size is
same as brake but
lever is thinner.
Domino socket bolts
L is brake, R is start
they hold the cable in the center of the lever
Garelli Start Cables
showing all the pieces
upper is aftermarket
lower one is original
Garelli start cable aftermarket installed
The step ferrule comes from the old cable.
Everything else is new.
More to follow…
Pinch Bolts
Many of the 8mm diameter pinch bolts (item P3c above) sold on the internet will slip if the bolt is not tightened with a pliers holding onto the round 8mm barrel. This is because the 5mm bolt does not have a dome shaped end. Myrons cuts a rounded dome in the 5mm pinch bolt. This makes it gently fold the wire into a curve when the bolt is tightened.
Domed pinch bolts hold better and don’t cut.
Domed and regular 5mm pinch bolts with 8mm barrels. At top, the tool that holds them for cutting and a M5x0.8 die.
You pay more for a Myrons pinch bolt, but you will get a much greater benefit. Safety (it won’t pop off when you slam on the brakes), and ease of installation (don’t normally need a pliers to hold the round barrel). You can feel the cable bending as the bolt is tightened. That gentle bending is what makes it not slip. See pictures at left.
The 5.5mm diameter pinch bolts (item P1 above) for throttles already have domes on their 3mm bolts. (cones actually). So they are designed to hold good, yet be small. Nonetheless, they often need to be soldered, in addition to the pinch bolt tightened as much as possible, in order to not slip.
Under construction ..
