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Installing a new cable
• Note the routing of the original cable.
• Check that the overall dimensions are the same as the old
one. Inner cable lengths may be slightly different, as the
old cables will have stretched slightly over time.
• Before installing the new cable, hold the cable upright
and use a few drops of a light 3 in 1 oil to lubricate the
inner cable. Move the inner up and down to ease the oil
down the cable.
• When the new cable is ready to be tted, route the cable
carefully and in most cases, as per the old cable, Make sure
the cable will comfortably reach its intended connection.
• If the original cable routing is via a heat source, make
sure that there is a suitable gap between the cable and the
heat source.
• If cable ties are required to route the cable, leave them
loose allowing the cable to move. Too tight and they will
restrict the operation of the cable and its ability to move
with the handlebars.
• For Push-Pull / Open-Close throttle cables, always
connect and adjust the pull/ open cable rst where
possible.
• Where nipples require lubrication in levers or linkages,
use a small amount of copper grease. Avoid using heavy
greases as these will attract dirt, restrict the movement
of the nipple and cause excessive wear and stress on the
nipple and cable.
• When the cable has been installed, check the steering
lock to lock and check the operation of the cable at both
extremes of steering. Check that the cable does not go
tight and that operation is not impaired. If one of the
above is true, check the cable routing, adjustment and that
all the nipples are located properly.
Maintenance
Cable maintenance is essential to prolong the life of the
cable and maintain the operation of the cable.
MX Bikes
After a race meeting or as often as possible after power
washing, remove the cables from the bike and ush
through with WD40. Keep ushing them through until the
uid runs clear. Once clean, lubricate the cable again with
a light 3 in 1 oil and check the cable routing. Also lubricate
nipples where required with Copper grease.
Trail Bikes
When servicing or after power washing, remove the
cables from the bike and ush through with WD40. Keep
ushing them through until the uid runs clear. Once clean,
lubricate the cable again with a light 3 in 1 oil and check
the cable routing. Also lubricate nipples where required
with Copper grease.
Road Bikes
At the beginning and end of the summer, remove the
cables and ush through with WD40. Once clean, lubricate
the cable with a light 3 in 1 general purpose oil and
lubricate nipples where required with Copper grease. Note
barrel nipples must be free to rotate in the lever blade.
Do not use heavy engine oils, chain lubricants or grease
to lubricate cables as this will attract dirt, increase cable
wear and reduce the operation of the cable. Remember:
Cables are a service item and should be replaced at
regular intervals. If you are in any doubt about replacing
or installing a cable please consult you’re nearest quali ed
motorcycle mechanic.
Tech Tips
The following recommendations are given as guide to you
help install and setup your cables and make sure you get
the best from Venhill products.