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Remaking
EXUP cables.
Words & pictures by Nuggitt
The price and scarcity of replacement
cables is something we'll all encounter at some time.
Nuggitt shows how to remake your cables for pennies
whilst using uprated materials to last longer than the
OEM items.
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FZR1000R 1990 Exup cables
(using original outer cable off the bike).
Both original cables are 765mm - inner cable length
from nipple to nipple. Ru model cables are 915mm.
Pull out the old inner cable.
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Fully screw in the cable adjuster. |
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New inner cables from ebay. Go for the
bicycle stainless steel versions. They're only a couple
of pounds including delivery. One length of cable will
do 2 exup cables.
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Dip the ends of the new cable into the hot
wax to stop the strands uncoiling. |
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Thread one 5.5mm nipple onto the cable. |
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Run the nipple up to the other end to where
the original nipple is. |
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Now thread new inner cable through the
outer cable. |
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Then thread the other nipple on. |
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Measure nipple to nipple length of 765mm. |
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Or 915mm for RU model. |
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Then tighten up the nipple at the end
where the other nipple is; which came attached with
the cable.
Of course if things go wrong here you'll end up with
a screwdriver stuck in your hand.......you've been warned! |
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Check measurements again and tighten up
the other nipple.
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Now cut off excess cable with a dremmel
type tool. Cut off the excess cable at the other end too. |
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The original nipple removed leaving the
remanufactured one. |
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Almost there......
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There ya go a brand new exup cable at
a fraction of the cost of OEM.
Of course, if the outer cables beyond repair, its also
possible to replace that too with a bicycle outer whilst
doing this task.
Now have a look in the other EXUP Valve sections on
how to repair the valve, what lube to use, and where
to get replacement parts in stainless steel! |
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to EXUP Valve Info» |
