Control Cables

 Cables for the Plover 86 can be a problem: The easy ones are the front brake, which is available pre-made, and the Speedo. This latter is available but expensive. However a Triumph Tiger cub cable is only a few inches longer and will fit just fine. Throttle and clutch unfortunately are not available and need to be made up from cable kits, a universal for the clutch but a dedicated throttle cable kit for the throttle. This is because the tiny nipple that slips into the carburettor slide is really too hard to fit yourself and these kits come with it already fitted.

Before trying to make any cable remove the old one fully. Measure the length of the inner and outer cables- including any nipples. Identify and source suitable nipple replacements for the new cable. Look closely at all the parts  on the old cable- measure the nipple size and watch out for ferrules, end bosses and adjusters- some of which, as in this case, can be slipped over a preformed cable but others may need to go on before the nipples are soldered. Don't get assembly in the wrong order! 

Throttle cable (twistgrip end)- note cable boss jammed down on ferrule and small barrel nipple at end.

End boss and ferrule separated

The universal kits come with an assortment of nipples and thats something you dont see everyday! However,  usually they wont have exactly the one you want, so if possible remove and reuse the old one from the existing cable. Some of these are actually formed of solid solder cast in place and this type obviously can't be removed but if its a soldered on steel nipple it should come off easily enough. Clamp the cable in a vice and heat the nipple with a butane gas torch (creme brulée type). You can use a soldering iron but it takes longer. As the solder melts push the nipple down the cable away from the "birds nest" or splayed wires that holds it on. Cut the cable and slide it off.

Throttle twistgrip nipple slides down the cable once  the solder has melted. Note splayed wire "birdcage" from the nipple recess. Cutting bowden cables can be done with bolt cutters or alternatively use a sharp cold-chisel to cut on something like the rear of a vice. If you're buying bolt cutters get the type with hardened jaws or they will develop a notch very quickly. Making up the new cable isnt too tricky provided you can cut the cable. Select all the bits you need including the correct gauge of bowden with appropriately sized outer sleeve. Throttle cables tend to be lightweight whereas brake and clutch cables are beefier. Cut the inner to length and fit the end ferrules. Slip the inner through the outer- Dont cut it to final length until its the nipple fitting stage. Fit any sleeves or adjusters and then solder one of the nipples. Slip the cable through the nipple and untwist the very end few mm. Push down on the end of the cable flattening it into the shallow depression on the nipple. Form a "birds nest"

that cant fit back through the nipple- its this bent wire that retains the nipple- the solder is just to stop it moving.

Bowdens are usually galvanised but some are stainless. These need different fluxes and solders so get the right combo. I use a cheap solder well as its so much easier but if youre going to use a soldering iron get a big one. Personally I avoid using a torch to solder because its easy to overheat the cable and turn it brittle.

Make sure the basket is in the nipple hollow and then pop the nipple and cable into flux, shake off any excess and then dip into the solder pot. Wait a second withdraw it and let it cool. There will be some solder or a few stray wires protruding so remove these carefuly with a file to give a smooth nipple and check it will fit easily in whatever attachment its intended for.

Lay out the cable and slip the nipple (and any fittings) onto the other end. Slide the nipple along to give the correct length (measured previously) and mark the inside position of the nipple on the cable with tape. Cut the cable outside the nipple leaving enough spare to form a birdsnest as at the other end. Hold the nipple in a vice,  poke the cable through up to the taped "stop" and splay the wires forming the nest. Pack the nest into the nipple hollow- check length again and then solder as above.