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Falcon 74 Throttle Cable

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Falcon 74 Throttle Cable

Post  scootsx2 on Tue Sep 20, 2016 3:25 am

What is a suitable replacement throttle cable for a 1956 Falcon 74 (8e engine)? Are any of the "universal" throttle cable kits, such as sold by Villiers Services, suitable or is there a cross over part from another bike that would work well?

scootsx2

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Join date : 2012-08-18
Location : St. Louis, Missouri USA

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cable options

Post  piston 197 on Tue Sep 20, 2016 6:07 am

Basically the throttle cable will be the same as any other cable fitted to a machine with a Villiers 8E engine, but the uniqueness of the Falcon cable was that it was green
Original cable part No from Romac was T445 or (TG445 if green) to suit 1956/7 machines , overall length was 3'3" , the earlier cable 1953-1955 bikes was 3'6" but no doubt this could be used , so if it was made for a Villiers 8E powered machine and is 3'3" or longer it will do the job ?
JH

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Cables

Post  kerabo on Tue Sep 20, 2016 6:28 am

Look up JJ Cables
He has the drawings of the originals for almost all bikes. Not always in green.
Ask for Teflon lined it make a nice smooth operation.
Or he will make to your dimensions.
I have now bought a kit to make my own as it's cheaper and you can get exact sizes.

Regards Ken

kerabo

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Location : 1950 Powerbike 56. 1960 Falcon 87. 1961 Trials 83 Special. Falcon 87 in bits. Falcon 81 Trials bitsa.

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cables..

Post  john87 on Tue Sep 20, 2016 10:01 am

Hi Ken,

How does the kit work then?? that would be a useful bit of kit!!

john..

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cables

Post  kerabo on Tue Sep 20, 2016 11:46 am

First I bought what looks like an inkwell that melts a pot of solder so you just dip it in. That was eBay China. Then as many metres of inner and outer cable as you want. The sleeves. nipples and adjusters you can buy bulk but there are lots of choices.
They are a company in the UK but I can't remember the name.
There are cable flairing tools but they are expensive.
When I remember the name I will put it on .
Regards Ken

kerabo

Posts : 1806
Join date : 2008-02-11
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Location : 1950 Powerbike 56. 1960 Falcon 87. 1961 Trials 83 Special. Falcon 87 in bits. Falcon 81 Trials bitsa.

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cables..

Post  john87 on Tue Sep 20, 2016 11:49 am

What you use for flux?? Bakers fluid or phosphoric acid or something??

john..

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cables

Post  kerabo on Tue Sep 20, 2016 12:16 pm

I used bakers fluid
Regards Ken

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Location : 1950 Powerbike 56. 1960 Falcon 87. 1961 Trials 83 Special. Falcon 87 in bits. Falcon 81 Trials bitsa.

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Post  john87 on Tue Sep 20, 2016 12:34 pm

Thought that was the stuff!! I have never soldered a nipple on.. Is it difficult to tin the wires, or no problem with the Bakers fluid??

john..

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Post  kerabo on Tue Sep 20, 2016 1:00 pm

Just a matter hid gently hearing the cable end and dip in the flux then submerge in the pot of melted solder for a few seconds and then let it drip away and done. You do need to make a clean cut on both inner and outer cable and you have to spread the inner cable ends before soldering.
Regards Ken

kerabo

Posts : 1806
Join date : 2008-02-11
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Location : 1950 Powerbike 56. 1960 Falcon 87. 1961 Trials 83 Special. Falcon 87 in bits. Falcon 81 Trials bitsa.

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cables

Post  john87 on Tue Sep 20, 2016 1:07 pm

Hmm, a clean cut...

The only time i have ever been able to do this was years ago when i bought a pair of SnapOn side cutters. They would cut it so cleanly you would not believe. I had about 10,000 worth of SnapOn stuff, but had to sell it all when i was skint once... Worst thing i have ever done...

The modern SnapOn stuff is not a patch on the early 1980's stuff though..

What is the cable flaring tool then?? i take it it is a gadget to flare the wires into the cone shape you have to make???

john

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cable

Post  kerabo on Tue Sep 20, 2016 1:14 pm

Sharpe chisle across a vice and one clean but

Ken

kerabo

Posts : 1806
Join date : 2008-02-11
Age : 66
Location : 1950 Powerbike 56. 1960 Falcon 87. 1961 Trials 83 Special. Falcon 87 in bits. Falcon 81 Trials bitsa.

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cable

Post  john87 on Tue Sep 20, 2016 1:28 pm

Ahhh......!!

john..

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Re: Falcon 74 Throttle Cable

Post  scootsx2 on Tue Sep 20, 2016 2:10 pm

kerabo wrote:Look up JJ Cables
He has the drawings of the originals for almost all bikes. Not always in green.
Ask for Teflon lined it make a nice smooth operation.
Or he will make to your dimensions.
I have now bought a kit to make my own as it's cheaper and you can get exact sizes.

Regards Ken

I have contacted JJ Cables and am awaiting their quotation. Thank you.

scootsx2

Posts : 79
Join date : 2012-08-18
Location : St. Louis, Missouri USA

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Cables

Post  kerabo on Tue Sep 20, 2016 7:27 pm

[quote="john87"]Hmm, a clean cut...

The only time i have ever been able to do this was years ago when i bought a pair of SnapOn side cutters. They would cut it so cleanly you would not believe. I had about 10,000 worth of SnapOn stuff, but had to sell it all when i was skint once... Worst thing i have ever done...

The modern SnapOn stuff is not a patch on the early 1980's stuff though..

What is the cable flaring tool then?? i take it it is a gadget to flare the wires into the cone shape you have to make???

john[/quote
The flaring tool is a pair of blocks with I think 1mm 1.5mm and2mm holes. It has a countersunk head. With the cable clamped there is a pin with the same countersunk shape. When hit it makes a Diamond of the cable end so when soldered it can't pass through the nipple.
search Venhill for cable parts. Don't get Stainless it won't solder.
Ken

kerabo

Posts : 1806
Join date : 2008-02-11
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Location : 1950 Powerbike 56. 1960 Falcon 87. 1961 Trials 83 Special. Falcon 87 in bits. Falcon 81 Trials bitsa.

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Cables

Post  john87 on Tue Sep 20, 2016 8:10 pm

Ha, I will have a look now.. I expect i could make one easy enough!!

john,,

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Re: Falcon 74 Throttle Cable

Post  scootsx2 on Tue Oct 18, 2016 1:47 pm

kerabo wrote:Look up JJ Cables
He has the drawings of the originals for almost all bikes. Not always in green.
Ask for Teflon lined it make a nice smooth operation.
Or he will make to your dimensions.
I have now bought a kit to make my own as it's cheaper and you can get exact sizes.

Regards Ken

I received a pair of the cables from JJ Cables. Fits perfectly and the price was very reasonable.

scootsx2

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Join date : 2012-08-18
Location : St. Louis, Missouri USA

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Re: Falcon 74 Throttle Cable

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