Connecting throttle and air control cables

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Robb2014

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Is there a trick to this or something? I've been trying to get these connected for the past hour and it keeps getting progressively harder. I've been connecting the throttle first as it's the easiest, but after I get the air control connected I can't get the needle valve and retaining clip in the hole. It's one of those things where you keep trying to invent different methods and end up feeling like the coyote trying to catch the road runner.
 
Finger strength. As Hobot would say it separates the men from the boys. Just leave the darn air slides/choke out and seal up the carb-top cable entrys. Whew !
 
Torontonian said:
Finger strength. As Hobot would say it separates the men from the boys. Just leave the darn air slides/choke out and seal up the carb-top cable entrys. Whew !
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I ended up making a tool. Took some 1" PVC and cut off about a one inch piece and cut a vertical slot so I could get it out afterwards. The problem I was having was after compressing the spring it would keep popping out the side when I went to put the needle valve in. The pvc keeps it from doing that. This made it a 2 minute job after I'd spent about an hour an a half with no success.
 
I like the part where a spring pops out of place and bruises your fingernail = !@#$%^&*(). Care to post a photo of said tool or a diagram for us ?
 
Torontonian said:
I like the part where a spring pops out of place and bruises your fingernail = !@#$%^&*(). Care to post a photo of said tool or a diagram for us ?
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Connecting throttle and air control cables


A thin 6" steel machinists ruler worked well to work the spring up into the "tool" and then hold it in place while I dropped the needle valve and clip in. I'm going to stick this thing in my tool pouch just in case. Ya know..., I got to thinking about Hobot and some of the others who have more than one Commando. I'd love to get another basket case for no other reason than everything will be about a hundred times easier the 2nd time around. Too bad they're so far and few between.

Torontonian said:
I like the part where a spring pops out of place and bruises your fingernail = !@#$%^&*(). ?
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That's a wonderful thing. Even more fun than when the spring launches itself across the garage into a pile of junk and you get to spend 15 or 20 minutes looking for it.
 
I love this sight...every time I am ready to post a question, someone else beats me to it....Ive tried, needle nose pliers on the cable, it seems to work but I think if you do it too much it may crimp....

In the end it was, throttle cable first, then spring, hold that up and drop in needle...close up the carb and work with pliers and fingers to seat the cables in the " junction" tube...

3x tried...success 1.
 
You must insure that all the adjustment is taken out of each cable. That is, the screw adjusters at the throttle and the carb, etc are all the way in. Also insure that the cable ferrules are seated all the way into their pockets. This gives you the most slack possible for the cable wire. You should be able to do it with only some difficulty. In my experience it is similarly difficult on all makes of bikes and carbs. Just something you have to live with with slide carbs.

JD75
 
I use hemostats to hold the springs compressed on the wire.

Dave
69S
 
christulin said:
Are roach clips the same as hemostats?
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Yes. I should know, of course. Don't want to burn your fingers, no?

Dave
69S
 
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