So yesterday I was talking about how much of a challenge running the new cables was (especially the shifter cables) due to the individual pipe/channels that were designed in this scoot. Here is a picture which shows the main problem area.
This is hardly recognizable unless you are looking up into the front fork tube of a scoot from this generation but here is what is going on. This is the bottom of the front fork tube. The shiny ring is where the bottom bearings will run. In the bottom center of the photo just above the red spot of primer you can see the clutch cable which runs freely at this point down the fork tube. Just to the right of that you can see the steel tube which encases the two shifter cables and at this point also the throttle cable. With all three of those cables running inside of that tube it is very tight and the cables do not want to move at all. This is made worse by the fact that new modern cables and housings are slightly larger than the old ones so the space is just crammed full. At the point of this photo you can see a hole in that steel tube. I have a copper wire running from outside to inside and in the background you can see one of the shifter cables which remains inside. This hole is where the throttle cable exits the tube and continues to the back of the scoot on its own course. The two shifter cables remain inside the tube for the rest of the journey to the back of the bike. As the throttle cable comes out of the tube at this point is gets pinched trying to exit the tube. Not so pinched that it inhibits the inner from moving freely but pinched enough that the throttle cable outer can not be slid up and down. Making any adjustments to the throttle cable is very difficult. Because of all of this complication there is no way the front fork can be installed until of the electrics, the engine and cables are set. So this scoot is going to be in a waiting pattern for a while until I solve the engine question.
In yesterday's post I talked about putting grease on the outers to help the cables navigate these tight spaces. Here is a photo of the greased cable outer ready to enter the tight down tube in the front fork. After getting the first cable down the tube the second one was much easier due to the grease. It will also protect the cables inside the tube over time.
Also yesterday I talked about clamping a vice grip on the end f the copper guide wire to secure the two outers tightly together in one train. Forget that! A far more simple and very effective answer is pictured here:
After a lot of pulling and teasing the frame cables were complete.
I have the brake cable nearly done as well and will post a few photos of that very soon. A few quirks on that install as well mostly related to the fact that the new cables are larger in diameter than the original cables.
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