Cold Christmas in the Garage

[Stuart]

Had some last minute xmas presents to buy and thought I'd shoot into town on the bike.
Weather was freezing and when I started the bike the knock was severe as expected. What wasn't expected however was the accompanying 'ringing tone' from the new exhaust Nothing annoying but certainly noticable. Maybe it'll go away when it soots up some.

Anyway, that was the least of my problems. I pulled out the town carpark to come home and the clutch cable went on me at the lever. That Silver solder repair I did some time back finally gave out
Still, I managed to limp home and now face a few cold hours putting the spare one I bought in Hamm on. Brrrrrr

[balboa_71]

Stuart,
When I had my Enfield, I was forced to carry cable spares because parts were difficult to find locally. I used to keep what I could in the little box on the left side of the bike behind ones leg. I think the only thing in there from the factory was a fuse holder and stop light switch. Clutch cables were crap, and there's some guy up north (Indiana) that makes better ones than stock.

Cris

[Stuart]

Yeah,
I had foolishly driven many miles without one and luckily had no trouble. Good job I bought one from the trader guy in Hamm. But yes, the quality isn't that good in general. I remeber when I got my panniers. They were rusty already! lol
I just put it down to them not knowing about the bad climate here.
There is a guy about 15 miles from here who has loads of cable stuff. I should get over there and see if he has any better inners.
http://www.britsandpieces.net/

[balboa_71]

Stuart,
When I moved back to the U.S. in '74 we had all sorts of shops selling used parts for Brit bikes. I even worked at our local BSA shop for a while, putting together new Triumphs, and cleaning out the "bone yard" for used spares. Now, it's all gone and those bikes that can be found go for a pretty penny. I remember when you could'nt give one away. Everyone now wants a Jap bike with no personality....just plastic.

Cris

[Stuart]

Yes Chris,
I guess there are two schools of thought on that front. Brit Bikes undoubtably have 'personality' but to some (and I may be one of them) that means they aren't always easy to fix up.
Having restored a Honda 400/4 in recent years it was a joy to find small arrows stamped on various parts telling me which parts went together. And, after working on some old Brit Bikes, it was pure joy to take a bolt out and not have the nut fall off the other side.

But my Dad used to run about on a Norton Dominator 99 whilst my uncles were both confirmed Bonnie men. Infact one still has his bike, a '61 Bonnie. I was brought up with the phrase 'Jap Crap' ringing in my ears and to be honest I don't think it's true. Their stuff isn't made to last but hey, I guess that's business 'ain't it?

I'll try and dig out a picture or two of this family's old Brit Bikes and post it here.
Picture Number 1. My Dad on his (mate's) Norton Domi 99. I'm told his had a slightly different reg now and was parked in the background. Apparently they both bought their bikes on the same day.

He's a shot of him fixing up a bike - London late 50's early 60's.

My Uncle on his Bonnie,

My first big bike. I was 18 when I got this Bonnie.

[Anorak_ian]

Instead of carrying a complete new clutch cable as a spare, try using a slip on barrel to replace the broken one. Simply slip over the inner cable (cable always goes at the leaver) and tighten with a screwdriver. This will save you space, and it's a quick road side repair.

Also carrying a new split link for your drive chain is a good idea. I keep one on my jacket zip slider so I will never loose it. When a chain snaps it aint nice miles away from nowhere.

Cheers
Ian

[Stuart]

A friend at work mentioned them just the other day. A solid nipple with grub screw to tighten against the cable.
I will put it on my Christmas List and hope Santa gets me one by tomorrow

[oldbmw]

Maybe you already know this, but if your cable is breaking near the barrel, most likely the barrel is not pivoting freely in the lever. This then bends the cable very time you use it. Eventually metal fatigue will cause the cable to break. To check, pull the lever slowly and look at the cable coming away from the barrel. If the cable flexes, bends or does not remain straight, it is bending instead of the barrel pivoting. keep the barrel well lubricated and free.
Second tip, fit new cables and keep the old ones as spares. you 'know' these will fit. ( best place to store them is alongside the existing cable already run ready to fit.) seal the ends to keep dirt and damp out.

[Stuart]

I had a look and there is a plastic shroud around the nipple which I guess lessens the need for lubrication. But I understand what you say about that being the week point. When it went before there, there was enough slack for me to be able to fit this new nipple I made. The problem was the cable had splayed out somewhat and I get the heat from silver soldering it de-tempered the normally stiff cable. I thought it may have lasted longer than it did though.
On the Enfield's you have to keep the grease nipple on the gearbox happy otherwise that cluch gets heavy!
I've heard the one about laying spare cables alongside old ones. May consider that for longer trips way in the future

[Anorak_ian]

Maybe it's time to look for a heavy duty cable? The Enfield cable is a bit weedy, the sort of thing you expect to find on a moped. A Harley Sportster cable should fit at both ends, and is way heavy duty. One of the things worth keeping when I was breaking my old bike.
There is an adjuster half way down the cable, good for lubrication. Not sure but I think it could have a nylon inner sleeve to aid movement (nylo cable).

Anyhow, it's Christmas Eve so I raise my glass and say "here's to the enlightened" "Cheers"

Ian

[Diesel Dave]

The best cables are the ones you make yourself.

One of the most rapid failures of Enfield Cables is the throttle, the twistgrip nipple jams in the rotor hole and then the cable bends rather than the nipple rotating in the housing.

Venhills sell all the parts you could ever wish for to make your own, if you take your time you will find the results better than any factory job.

On the 4 speed clutch cable, it is possble to drill, tap and install a grease nipple into the mid point adjuster, but be aware that the export cable has a teflon liner anyway.

You will find with Enfield cables that it's the outer that compresses rather than the inner cable streaches.

Being a cheapskate I make my own nipples in the lathe and buy stainless cable from a yacht chandlers. I use black wiring loom wrap to mend any outer breaches. Bicycle gear wires make good throttle wires.

I find the best way to solder on a nipple is first tin the end of the cable, I have made a small solder pot from a scrap of ally and heat it up with my plumbing soldering blowlamp. Clean the end of the cable with some wire wool and dip it in flux then into the molten solder in the pot for several seconds to ensure that the cable is heated properly by the molten solder.

I use non-lead plumbers solder - cheap and hard.

Thread the soldered end of the cable through the nipple and then smack the end with a punch to splay the tip. Flux again and heat the nipple only with the tip of a pencil torch, when you see the solder flas add more till the void is filled. Dress with a file and jobs a good un.

Never let the flame hit the cable directly or the temper will be lost.

I have tested some home made cables against bought ones and guess which ones proved stronger.

If you reuse the clutch outer I find it easier to strip out the nylon liner, use a heavier gauge cable and fit a grease nipple - BTW watch the side cover on your gearbox when pulling the clutch in - see it flex outwards; never happened on the brit versions. There are many ways to improve the clutch, start with the roller pad and splitting the operating rod and adding a ball bearing between the rod parts - this prevents the rod flex that does happen

I always carry a cable repair kit with solderless (screw retained) nipples, but the toolbox does offer space to store spares - just be aware of the damp that tends to gather in these. I wrap mine in a plastic bag first, use one of those litte silica gel bags too.

All the best
Dave

[balboa_71]

Stuart,
Thanks for posting the photos of the older bikes that you grew up with. Nothing can replace the memories and good times of those days!!!

Cris

[Stuart]

Well I did the cable repair. It went surprisingly well. Must get another spare now. The outer was breaking up on the old cable so I may not use that again.

[richard coles]

hi ,please make sure your inner cables do NOT have a coating on them as oil will cause it to swell with inevitable consequences. The coating is added to do away with the need to oil.
Have a happy new year
Rich