Contents: 
A. 70’s – 80’s Magura Parts
B. Magura Moped Controls
C. Service Information

 

Magura was founded in 1893 by inventor Gustav Magenwirth as a manufacturer of gasoline motors, hydraulic press pumps and water pressure devices. Since 1923 in Bad Urach, Germany, they have produced handlebars and handlebar controls for mopeds and motorcycles. They are an industry leader, and still produce handlebar controls for all major makes. Since the 1970s, the company has also made many products for the bicycle industry. The name Magura is from Magenwirth and Urach. The logo is from a rotary rack developed in 1930.

Wrap-around and Slide-type: There are two main types, wrap around where the throttle cable wire wraps around and attaches to the twist tube, and slide type where the throttle cable attaches to a block that slides in a spiral slot in the twist tube.

70’s and 80’s: It is a subtle difference, but side by side you can see there are two different folded aluminum original Magura levers. The 1980’s “late” right lever, on the left, is longer and straighter than the 1970’s “early” left lever, on the right. When they are not side by side, it is really hard to notice. 

 

 

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A. ’70’s-80’s Magura Parts

 

Price colors: dark green is good-used, green is new, none means not available

 
1. 70’s left control, 2. 70’s right closed-type control,
3. 80’s right open-type, 4. 80’s right slide-type

 

 

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#    price   1. Left Levers

1a  $38.0 original folded aluminum used no ball
1b  $25.0 original folded aluminum used straight
1c   $29.0 original folded aluminum used long
1d  none  original folded aluminum black
1e  $36.0 original cast (solid) aluminum used
1g  $25.0 original folded aluminum Agis black
1p  $26.0 original folded alum. with parking brake
1ar $12.0 folded steel generic no ball, for 6a with 6e
1cr $24.0 folded aluminum generic long
1dr none  folded aluminum generic black
1er none  cast (solid) aluminum TCCD
1bs $20.0 2b upside down, for 6a upside down
1bd $28.0 2b drilled to 6/6, upside down, for 6a with 6e
1gd $14.0 2g drilled to 6/6, for 6a with 6e

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#    price   2. Right Levers
2a  $34.0 original folded aluminum used no ball
2b  $20.0 original folded aluminum
2bu $15.0 original folded aluminum used straight
2c   $20.0 original folded aluminum used long
2d  $32.0 original folded aluminum used black
2e  $25.0 original cast (solid) aluminum used
2g  $12.0 original folded aluminum Agis black
2ar $12.0 folded steel  generic no ball
2cr  none  folded aluminum generic long
2dr  none  folded aluminum generic black
2er  none  cast aluminum TCCD
2bd $22.0 2b drilled to 6/6, for 6a with 6e
2gd $14.0 2g drilled to 6/6, for 6a with 6e

#    price   2. Lever sets R and L: with item #s
Sgb $30.0 lever set black 2gd 1gd 6c 6c 7c 7c
Sb   $44.0 lever set short 2b 2bd 6e
Sbb $38.0 lever set short 2b 2b left bolt flipped

All of these levers interchange and are 12mm wide at the pivot. Original levers have a 6 mm top hole and a 5 mm bottom hole. Some bottoms are the same as tops, others have a cable slot.

Flipping (using a right lever on the left side or visa versa): Right and left interchange when flipped (bottom becomes top). If the lever is flipped the pivot bolt must also be flipped, unless the 5 hole is drilled to 6 and the 6/5 pivot bolt changed to 6/6.

 

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#    price   3. Lower right thumb levers
3x  $22.0 right thumb lever original, locks-in off bar
3a  $26.0 choke trigger and spring for early Tomos A3
3b  $22.0 right thumb lever replacement, locks-in off bar
3c  $10.0 clamp-on metal lever substitute for #3 or 3b

 

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#    price   4. Twist tubes for grip length 100 or 115

4    $32.0 100 original white (cable loads from front)
4b  $27.0 100 original black (cable loads from front)
4c  none  115 original black (cable loads from front)
4r  $25.0 100 Agis black (cable loads from back)

 

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#    price   5 – 11. Hardware
 
5    $3.00 friction plate to make throttle stick (leave off)
6a  $4-$2 pivot bolt 6/5 orig slot dome M5 x 20 ∅6 x 8.5
6b  $1.20 pivot bolt 6/6  allen short    M6 x 20 ∅6 x 2.0
6c  $3.00 pivot bolt 6/6  black phillips M5 x 25 ∅6 x 11.5
6d  $6.00 pivot bolt 6/6  6a with 6e    M5 x 20 ∅6 x 11.5
6e  $4.50 adapter sleeve changes 6a to 6d, ∅5 ∅6 x 3.0
6f   $0.70 pivot bolt 6/6  allen head     M6 x 20 not smooth
6g  $0.80 pivot bolt 6/6  phillips head M6 x 20 not smooth
7a  $1.00 pivot nut M5 plastic-lock original light gray
7b  $1.00 pivot nut M5 plastic-lock original black
7c  $0.55 pivot nut M5 metal nylock
7d  $0.90 pivot nut M6 metal nylock
7e  $1.00 pivot nut M5 metal nylock black
8    $7.50 left return spring
8b  $2.00 R or L return spring (not for solid cast levers)
9    $3.00 right return spring
10s $2.00 clamp screw M6x16 slot dome head
10a $0.70 clamp screw M6x16 allen head (Peugeot)
11  $4.00 socket bolt  aka cable anchor/adapter

For best performance, the pivot bolt should fit and be smooth where the lever rubs at.

 

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#    price   12. Left housings: with brake switch hole

12a $15.0 70’s silver
12b $15.0 70’s black
12c $15.0 70’s silver no start lever (74-79 Tomos)
12d $17.0 70’s black no start lever (78-79 Tomos)

12e $22.0 80’s silver with mirror hole
12f  $22.0 80’s black with mirror hole
12g $15.0 80’s silver no start lever (80-84 Tomos)
12h $15.0 80’s black no start lever (84-85 Tomos)

#    price   12. Left housings with threaded brake cable hole

12p $40.0 70’s silver (Peugeot and Solex)
12q  N/A    80’s silver (Peugeot and Solex)

#    price   12. Left housings no brake light switch hole

12n $10.0 80’s silver no brake light switch hole

 

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#    price   13. Right housings with brake switch hole
 
13a none  70’s silver
13e none  80’s silver
13f  $89.0 80’s black

13c $79.0 70’s silver with choke slot (74-79 Tomos)
13g $790 80’s silver with choke slot (80-85 Tomos)
13h $75.0 80’s black with choke slot

’74-85 Tomos Thumb button activates choke by allowing grip to twist in reverse.

#    price   13. Right housings with threaded brake cable hole

13p $69.0 70’s silver (76-79 Peugeot)
13q $75.0 80’s silver (80-83 Peugeot)

#    price   13. Right housings no brake switch hole

13n $45.0 70’s or 80’s silver (Euro version)

 

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#    price   14 – 15. Grips (singles)

14   $3.00 left  grip  100 mm black ribbed original
14b $11.0 left  grip  100 mm black waffle used
14c $6.00 left  grip  115 mm black block original
15   $18.0 right grip 100 mm black ribbed original
15b $14.0 right grip 100 mm black waffle used
15c $9.00 right grip 115 mm black block original

 

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#    price   16 – 18. Left lower levers:
16   $14.0 start lever new black plastic with screw
16b $32.0 start lever aluminum long w/screw (Puch 2-spd)
17   $2.00 pinch screw 4mm
18   $3.00 pivot pin
18b $1.00 pivot pin substitute screw M4x20

 

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#    price   20. Grip sets

20   $12.0 grip set 105 mm #14, 15 ribbed replica
20g $19.0 grip set 105 mm #14, 15 ribbed grey
20c $12.0 grip set 115 mm 14c, 15c block original

 

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#    price   21. Right housings: slide type

21b $34.0 black for slotted-slide (some 84-86 Puch)
21   $25.0 black for screw-slide (some 78-83 Puch)

 

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#    price   22 – 25. Slide throttle parts:

22   $3.00 roll pin for twist tube 2.15 x 26 for 2.0 hole
23   $3.00 screw for sliding block (some 78-83 Puch)
24   $15.0 screw type slide (some 78-83 Puch)
24b none  slot type slide (all 84-86 Puch)
25   $28.0 twist tube Puch slide-type plastic

Magura slider: left is worn, right is new

 

 

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#    price   R. Right controls   $$ is new, $$ is good-used
with threaded brake light switch hole (BLSH), unless noted

R1    none  70’s silver
R1b  none  70’s black
R2   $95.0 70’s silver, auto-choke (74-79 Tomos)
R2b  none  70’s black, auto-choke (78-79 Tomos)

R3   $130  80’s silver
R3b $120  80’s black
R3r  $110  Agis black
R4    none  80’s silver, auto-choke (80-85 Tomos)

R4b  none  80’s black, auto-choke (84-85 Tomos)
R4r  $100  Agis black, auto-choke
R5p  none  70’s silver, threaded brake cable hole (Peugeot)
R5q none  80’s silver, threaded brake cable hole (Peugeot)

R6b  $110  70’s black open-type wrap-around
R7b  none  80’s black open-type wrap-around
R8    $110  80’s black slide-type (Puch Maxi Luxe)
R8c  none  80s blk slide-type cast lever (Magnum)

 

 

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#    price   L. Left controls   $$ is new, $$ is good-used
with threaded brake light switch hole (BLSH), unless noted

L1   $62.0 70’s silver
L1b $75.0 70’s black
L2   $59.0 70’s silver brake only (74-79 Tomos)
L2b $60.0 70’s black brake only (78-79 Tomos)
 
L3   $77.0 80’s silver
L3b $60.0 80’s black
L4   $59.0 80’s silv brake only (80-85 Tomos)
L4b $59.0 80’s blk brake only (84-85 Tomos)

L4p $42.0 80’s park-brake, no BLSH (Tomos trike)
L4r  $39.0 80’s black Agis threaded brake cable hole
L5p  N/A    70’s silver, threaded brake cable hole (Peug)
L5q  N/A    80’s silver, threaded brake cable hole (Peug)
 
L6    N/A    80’s black (78-84 Puch Maxi Luxe)
L6e $60.0 70’s black (78-79 Puch Magnum)
L6c $68.0 80’s black (80-84 Puch Magnum)
L8   $24.0 start only (Sachs 505 foot brake)

 

 

 

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B. Magura Moped Controls 

 

 

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Magura “Open Wrap Around” silver controls are used on 1950’s and 1960’s Puch, Tomos, Sears Allstate, and many others. Some are cast aluminum levers, and some are folded sheet aluminum.

Most of these did not have threaded holes for brake light switches.

Ball-end levers began in the 1970’s, for safety.  

 

 

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Magura “Open Wrap Around” black controls were on 1980’s Euro models, but not on US models.

Like the other Magura wrap around throttle controls, the twist tube has a groove that locks onto a tab in the housing. The two are locked together first, then slid onto the handlebar. Once on the handlebar they cannot become separated.

These have a plain hole with bottom, for the brake cable. Most do not have a hole for the a brake light switch.

 

 

 

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Peugeot or Not Peugeot: There are two ways to stop the brake cables. The Peugeot way is to have 6mm threaded bottomless holes in the housings with 6mm adjusters stopping the cables. The non-Peugeot way is to have the housings stop the cables (or the inline Magura-type adjuster) with a slotted recess (hole with a bottom) instead of threads. You can convert to Peugeot style by drilling and tapping to M6-1.0 thread. But there is almost no adjustment range (because most of the hole is already too big, 7mm).

 

 

 

 

 

 

 

 

 

 

 

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Magura “Wrap Around” silver controls are used on 1970’s Batavus, Colombia, Flandria, Foxi, Flying Dutchman, Hercules, JC Penney, Kreidler, KTM, Kynast, Murray, Odyssey, Puch, Sachs, Sears, Sparta, 74-85 Tomos, and others. These US models all had threaded holes for brake light switches. Most Euro and Canada models did not have brake light switch holes. 

The brake cable holes on both sides have two versions, M6 threaded bottomless (Peugeot style), or 7mm plain hole with bottom (non-Peugeot style). 

These controls on US models all had ball-end levers except for Sears Free Spirit.

 

 

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Magura-clone “Wrap Around” black controls are used on 1979-85 Tomos Silver Bullet. They are made in Yugoslavia to be Magura-compatible. 

The brake cable holes are 7mm plain with bottoms. 

 

 

 

 

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Magura “Late Wrap Around” silver controls are used on 1980’s Colombia, Hercules, Murray, Puch, Sachs, 79-83 Trac, and others. The housings are thicker and less rounded. The left has a mirror hole. US models had threaded holes for brake light switches. But most Euro and Canada models did not have brake light switch holes. In these photos you cannot tell if there are brake switch holes or not.

The brake cable holes on both sides have two versions, M6 threaded bottomless (Peugeot style), or 7mm plain hole with bottom (non-Peugeot style). 

 

 

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Magura “Late Wrap Around” black controls are used on 80-83 Puch Maxi, 80-85 Sachs (Hercules) and others.

The brake cable holes are 7mm plain with bottoms. 

 

 

 

 

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Puch-Magura “Sliding Block” black, used on 78-86 Puch deluxe models. 

Most of these are the early, common kind with a screw on the slider holding holding the cable wire. The cable wire itself has no upper end piece. It  takes a “universal” or “single ended” throttle cable.

Some of these are the late, uncommon kind with no screw on the slider. Instead the cable wire has an upper end piece 3mm “inline barrel” soldered onto it. The cable is specific to that set-up, and is “double ended”.

The brake cable holes are 7mm plain with bottoms.

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C. Service Information

 

 

 

Magura Wrap-Around Throttle

As mentioned above, the pieces snap together, but only when removed from the handlebar.

Twist tube: The throttle housing has a tongue that goes into a groove in the twist tube. The two pieces are first locked together while off the handlebar, and then slid on as a unit. Then the twist tube is kept from moving sideways. 

Thumb trigger: Not all mopeds have this, but all the wrap-around housings have a provision for it. This is also called a choke lever or a decomp lever. The trigger has half-circle-shaped posts that slide into slots in the throttle housing, but only when off the handlebar, and in the “squeezed past max” position. Once on, the handlebar prevents it from detaching.

Tomos A3 auto choke thumb button: This button, when pushed in, lets the throttle cable go all the way slack for cold starting.  When it is not pushed in, it allows the cable to stay a little taut for normal idling. Idle speed is adjusted by the tightness of the throttle cable, at the handlebar by the Magura type cable adjuster.

 

Installing a throttle cable: With an original Magura twist tube, the cable installs from the outer side, just behind the grip. Turn the grip forward to the closed position. Locate where the cable end is. Peel the flange of the grip there back with your thumb, and hold it there. With the other hand, place the sideways barrel end of the throttle cable into the cavity. Lay the wire over the ridge, and wrap it around the curved guide. When pulled taut it should fall into it’s groove. The throttle should pull the wire and move free.

With a Magura-clone twist tube, the cable installs from the inner side. So the twist tube has to be removed. That means the whole throttle has to be removed from the handlebar. But the cable is more protected.  

 

How to install the throttle cable:

 

 

 

 

 

 

 

 

 

 

 

 

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Worn throttle cable groove: The curved cable guide groove can become worn in the middle. It can become so bad that the throttle feels like a hack saw and makes a ripping sound like a zipper. When that happens the cable will soon be cut through and break. The cause of the worn groove is lack of lubrication. Moped cables and controls need oil occasionally.

 

 

 

 

 

 

 

 

 

The remedy is to re-cut the bottom of the curved guide. The best tool is a masonry hack saw blade. It has the exact width and round shape. The linear saw is moved in a curved motion. The bottom of the channel is visually checked every few strokes, to see what areas need more cutting.

 

 

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Installing a Magura brake lever spring.

 

 

 

Lubrication: Lube the cables and controls with a drip oil, like 3-in-1 or Tri Flow or any high tech lubricant. Tri Flow is thin so it penetrates in and clings to metal, like WD40. But after awhile when most of the liquid drys up, it leaves behind microscopic Teflon particles embedded in the metal surface.   

Making custom cables: Here are the distances of the exposed cable wires, for Magura wrap-around type moped controls.