Hi all
First job of the day and stuck already.
The front brake outer cable is 15mm too long when compared to the old one, making it impossible to fit the cable at the lever end.
The new one is from Feked.
The old one may have been a tad too long also.
So todays quest for help is how do i shorten the outer cable without making a mess of it please,
Also can anyone tell me the correct routing for the cable please.
Normally the cable runs through a hole in the bottom yoke.
The way I shorten the cable outer is with a Dremel cutting disc, taking my time.
You have to cut along the line of the cable (sounds like 15mm in your case) first to create a weak point that will allow you to fracture the windings later, then you cut at the point you need for correct length.
Once you have cut it to to length you can use pliers to unwind the cable (brake and clutch cable outers are quite thick compared with throttle and choke cables and if you try to unwind them without weakening it first you risk damaging the inner cable which then frays and becomes trash.
Most modern cables have a nylon liner so that if you cut slowly, inspecting constantly you will get warning before you get through the outer case winding.
Take your time and you will be fine.
Neil's method is probably better than the way I've always done it before I had a Dremel. I'd pull off the ferrule on the end then with a Stanley knife trim off the outer sheaving down to where I intended to shorten the outer to. Then carefully use a pair of side cutters to persuade the end of the outer winding to separate enough to get a hold of it with a pair of pliers. Then unwind the outer down as far as you need and snip it off with a pair of side cutters.
Whatever method you use there is always a problem with ferrule. When the cable was made it has been crimped over the end of the outer and will no longer slide over the end of the shortened outer. I've usually ended up trimming the outer sheaving back just enough to allow the ferrule to slide over the bare inner and butt against the sheaving. Done carefully it look ok.
Hi all
Well guys, its a success,This is how it went.
Cut the plastic cover at the top of the ferrule with a stanley, warmed the ferrule up with a small blowtorch and pulled it off with no damage, removed the plastic inside.
Cut plastic cover back to required length, and as i dont have a dremel, proceeded to weaken the windings on the bench grinder, ;D, this went ok, so managed to pick the windings off bit by bit, no cable damage thankfully.
Ferrule slid back onto the casing ok.You would never know, would you?
Many many thanks to Neil and Derek for the info received, i used a combo of both.
Mark
No-one considered doing it properly and resoldering the cable nipple on the correct length cable?
Quote from: V500 on 08 Mar, 2025, 17:05 No-one considered doing it properly and resoldering the cable nipple on the correct length cable?
An effective and tidy remedy has been achieved, why mess with the inner cable.
Quote from: Mark@Wales on 08 Mar, 2025, 14:45 Hi all
Well guys, it's a success,This is how it went.
Nicely done. Well done :)
Good job
Not every one has a solder pot and the correct fluxes to redo the nipples. If you had to shorten the inner you would have no choice.
If a beginner I would not suggest you doing the front brake as an intro.
I have the stuff and do my own (I have some Venhill kits) but to trim the outer of an already made cable is no big deal and this method is safer.