SuzukiSavage.com /cgi-bin/YaBB.pl General Category >> The Cafe >> Extending a throttle cable /cgi-bin/YaBB.pl?num=1503925236 Message started by Eegore on 08/28/17 at 06:00:36

Title: Extending a throttle cable Post by Eegore on 08/28/17 at 06:00:36  Ok so this isn't going on a motorcycle.  I am using a throttle assembly from a bike and hooking it to a chainsaw.  The issue is that the cable ends do not match obviously so I am thinking the best bet is hooking the two together.  The cable coming out of the chainsaw needs to be spliced/clamped whatever to the cable coming off the bike throttle.  The cable travels about 1/2 inch.  Any ideas?

Title: Re: Extending a throttle cable Post by Dave on 08/28/17 at 06:13:45 You can either get a throttle cable kit from Venhill: http://www.venhillusa.com/venhill-universal-motorcycle-throttle-cable-kit-1924.html Or you can go to a good bicycle repair shop and buy the needed inner/outer cable and make your own ends out of brass.  I really like the bicycle stuff as it is often teflon lined and works really smoothly.  The stainless cables do require a special flux to make the solder stick.  I have also found that it is really easy to overheat a cable when you attempt to tin the end of the cable using a torch - it is easier to heat up a pool of solder on a scrap piece of metal - then dip the flux coated cable end in the solder pool until it is tinned.

Title: Re: Extending a throttle cable Post by Eegore on 08/28/17 at 06:35:35  I was hoping there was some sort of crimp method.    I have the original cables but they aren't connected.  Are you suggesting I just strip out the current cables and try to make a custom length?

Title: Re: Extending a throttle cable Post by Dave on 08/28/17 at 06:45:24 Yes.....build your own cable. Vehnill has some cable ends with set screws - look through their stuff. http://www.venhillusa.com/products/cable-kits-and-parts.html?p=2

Title: Re: Extending a throttle cable Post by Eegore on 08/28/17 at 06:47:53  Ok I will check it out.  I don't know how the chainsaw cable connects to its internal component, hopefully its an easy attachment.

Title: Re: Extending a throttle cable Post by Dave on 08/28/17 at 07:00:12 Chainsaws can either be a very stiff bent wire between the trigger and the throttle - or they could be a cable.

Title: Re: Extending a throttle cable Post by Eegore on 08/28/17 at 07:09:49  Its a cable for sure.  I have the trigger/safety mechanism removed and the cable end is sticking out, its just not long enough.    If I can get to the internal connection without breaking anything and see how it connects then I'm good.  if not I have to hook the two together just outside of the chainsaw housing.

Title: Re: Extending a throttle cable Post by justin_o_guy2 on 08/28/17 at 09:22:30 You might have to build a bridge between the shielding coils that the connected actuator wires can travel in. Look at copper tubing fittings.

Title: Re: Extending a throttle cable Post by Eegore on 08/28/17 at 09:52:48  So the cable coming out of the chainsaw needs to be reinforced. At the end of the insulating cover there is a plastic block that keeps that insulated section from pulling out of the housing.    I will most likely need to keep that section of chainsaw handle that holds it in place and connect the cables together after, or fabricate a custom cable if I can.  I really wanted to remove all of the original handle trigger assembly.

Title: Re: Extending a throttle cable Post by Eegore on 09/03/17 at 10:37:34  So his is specifically my problem.  I need to clamp the smaller cable from the chainsaw to the larger throttle cable.  Running a whole new cable isn't an option unfortunately.    I also need to come up with a way to secure the throttle cable feed inside that handle but for now I need some method to allow the cables to connect and move 1 inch.  I contacted the website linked here and dropped by 3 bicycle shops and nobody had a method to secure two cables together.  So I'm still looking for ideas here.

Title: Re: Extending a throttle cable Post by justin_o_guy2 on 09/03/17 at 10:57:26 Get the end of the sheath out of the cup in the handle. Get the gray cap off the extension. Chop the BB off? Maybe, it could be a friend.. depends.. A piece of copper, I like the connectors, they are stiff. Tubing slipped into the ends, with a slot for fitting. The end you're adding to, clean up the curved tube and solder. The old end, clean, fit, epoxy and crimp. Connecting the cables can be as simple as cleaning and soldering or a splice and solder. How long you need it to last is the determining factor. Build a mount block and secure in the handle. The curved end is something to work with. A single strand of copper wire wrapped around the cables, fluxed, and soldered, will make a good connection. After the parts are scrounged, about three hours.

Title: Re: Extending a throttle cable Post by wakosama on 09/03/17 at 11:59:13 knarps?   https://www.google.com/search?q=knarps&source=lnms&tbm=isch&sa=X&ved=0ahUKEwi0zJPw2InWAhUhiFQKHcXsB5UQ_AUIDCgD&biw=909&bih=470

Title: Re: Extending a throttle cable Post by Eegore on 09/03/17 at 12:43:01  I've never soldered before, if I have time to go buy a kit and learn how that might be the way to go.  If I can get a knarp to fit in there it might work.  I'm surprised there's no sleeve out there that could be crimped.

Title: Re: Extending a throttle cable Post by justin_o_guy2 on 09/03/17 at 20:54:54 How many would get sold in a year? 5? Phhht.. Just connecting the two cables won't solve it. I described how to connect the housings.

Title: Re: Extending a throttle cable Post by Eegore on 09/04/17 at 17:55:58  Why wont connecting the cables work?    They would sit within the handle of the chainsaw.

Title: Re: Extending a throttle cable Post by justin_o_guy2 on 09/04/17 at 19:48:55 Try it. Might be a great solution. I don't have a mental image of the whole project.

Title: Re: Extending a throttle cable Post by MMRanch on 09/04/17 at 19:50:25 My chainsaw has a solid wire that looks like electric fence wire ...  ::) It does have fancy bends on both ends ... like ya might make with small pliers .  :-?

Title: Re: Extending a throttle cable Post by Eegore on 09/15/17 at 12:06:34  Its called a cable crimp.    A small piece of aluminum with two holes in it for each cable to slide into.  Crimp it and they are connected.

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