Overlander Equipment

Motorcycle Cables: Vintage, Veteran and Classic


Low friction "slippery cables" are high quality PTFE lined to give low operating force, low maintenance and long life, at a price similar or cheaper than Japanese cables of much inferior performance.

Each cable is supplied with a nipple assortment to suit most applications. Cables are not normally custom built, but can be made to specification if the demand requires. The standard length is 1.5m. This is the length of the outer cable (conduit). The inner length being 200mm longer than the conduit. The inners are 7x7 galvanised high tensile steel for AT and AC series and 1x19 galvanised high tensile steel for AB series.

Size and length codes:

AT.... Throttle, choke and timing etc. AC....Clutch and light brake. AB...Brake and heavy clutch

AT 3/16" 5mm 7/32" 5.4mm  0.58" 1.47mm
AC 7/32" 5.4mm 1/4" 6.4mm  0.07 1.77mm
AB 1/4" 6.4mm  5/16" 8.0mm 0.09 3.2mm
PRICES STANDARD 1.5 meters  SHORT 1.0 meters LONG 2.0 meters
AT (throttle) POA

AC (clutch) POA

AB (brake) POA
Postage and handling costs are 1-2, $4. 00 3-5, $5.00 6-10 , $7.00 11 or more, $7.00


The first operation is to trim the outer to length. If you are replacing an existing cable it is just a matter of copying the existing cable lengths . With sharp side cutters snip the outer to length after pulling the inner well clear of the trim point, push the inner back through. Fit the end caps .The maximum load on the control system is at the lever end. The most common failure is the separating of the nipple from the cable. This is best prevented by silver soldering the nipple at the lever end. Ordinary solder will do but will not be as good. Pull out about 150 mm of inner and slip on the correct size nipple. slightly burr the end of the cable to increase its diameter. Coat the cable and nipple with flux. Hold the cable in a vice so that the nipple hangs down against the burred end. With a very soft flame gently heat the nipple by waving the flame over it. When the flux melts apply the solder. Avoid over heating, getting the cable red hot will destroy the strength. Let the cable cool in air, do not quench in water. There is no danger of melting the PTFE liner.

In some cases the engine end of the cable will be special and will have to be removed from the old cable and reused. If this has been soft soldered, this method must be used for re assembly. Proceed as for the lever end. At times it is difficult to find oversize conduit for the AT cables, this has to be large enough to install the liner. As an alternative AC conduit is used. To fit the AT end caps cut away the plastic sheath for about 6 mm to allow the cap to fit. The only maintenance is periodic lubrication as for unlined cables, for many years of trouble free service.

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