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Inner Throttle/ Cable Lengths: ZL 400 Moderate Handlebar height:

Trojan441 Oct 7, 2019

  1. Trojan441

    Trojan441 Well-Known Member

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    I have previously had to cut n' temporary repair both opening n' closing Throttle cables with nipples fixed by screws! Even though on the closing cable I only cut off half an inch cable length. Problem is in combination with the other cut cable & even with adjustment to the Outer cable length, ( all Outer cable adjustment shortened), I have not enough free length Inner cable left! SO I have ordered two Inner cable kits off Ebay, they are 40 inch in length. Just hoping this is enough as it looks like the old Inner cables , might have been 40 1/2 inches long!
    Anybody got a similar length in measurement?

    Sports ZX 400s/600s are given as 33 1/2 inches approx! Shots taken 21/04/2019 @ 6:38 am Ramsgate harbour, out for an early morning ride covered 143 miles by the time I got back home 11:00 pm @ night!
    Headlight bulb, Osram H4 Night breaker really impressed with it so far!
    20190421_063816.jpg 20190421_063714.jpg 20190421_063728.jpg
     
    Last edited: Oct 7, 2019
    R. J. likes this.
  2. R. J.

    R. J. Supporting Member

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    :hello: At what points did you measure your throttle cables. ZL 900 are 42 inches long and ZL 1000 are 45 inches long. I measured them from ferrule to ferrule.
     
  3. Trojan441

    Trojan441 Well-Known Member

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    I measured the Inner cables once removed, the outer cables ferrule to ferrule are 31 1/2 with adjusters screwed in & each bent metal section amount to 2 3/4 inches so that's 31 1/2 plus 5 1/2 inches, 37 inches before adjustment to lengthen the outer cable. The second Outer cable is 31 3/4 plus 5 1/2 inches for the two metal sections, 37 1/4 inches! The Inner cable is 2 1/2 inches longer now on one, probably before cut 3 inches and 3 1/2 on the other. If the cables are dead on 40 inches I will be in the same position, so I hope each cable is slightly longer say by a cm each otherwise it seems like I will have to re-order inner cable lengths. Unfortunately I measured the shorter inner cable. In the USA U have accesss to a lot of gear and stuff we don't here, I blame the EU especially on the chemical front re paints and associated stuff! I am going to look @ re-ordering , but most on EBay have the wrong type of nipple for the carb' mechanism end!
     
    R. J. likes this.
  4. R. J.

    R. J. Supporting Member

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    :hello: Back in the 70s in PA we had a few Dealers that would make throttle and brake cables.
     
  5. Trojan441

    Trojan441 Well-Known Member

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    We
    We still do here, but when I am more flushed with cash I will get a professional cable making kit!
     
    R. J. likes this.
  6. Trojan441

    Trojan441 Well-Known Member

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    The Vendor of the cables lied on Ebay they are not 40", but a metre which is 39.37 inches so I am screwed n' have ordered a longer piece of Inner cable to make the length up!
     
  7. Trojan441

    Trojan441 Well-Known Member

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    Update strategy : I'm getting cables with small nipples n' soldering little recessed barrel nipples on the ends to fit the Keihin carburettor activation mechanism lever rail system!
     

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