How To Make Custom Motorcycle Cables - Throttle

In this video, I'll show you how I made a set of custom throttle cables for my Royal Enfield Interceptor 650. Obviously, you can do with this any motorcycle and it's a super handy skill to learn. This video focuses mainly on the process of prepping soldering your custom cables.

Thanks to the team at Venhill Engineering and Solder Connection for helping me in my research for this project.

Performance Mods:
***Disclaimer***
I have no affiliation with any of these companies or products. Please feel free to use these links as part of your research :)

Performance Mods:
- DNA Air Filter (stage II with open bracket)

- Booster Plug fuel system

- Scorpion Red Power pipes (please note this link is for the BLACK version, I can’t see the sliver anymore)

Hitchcock's Free Flowing Header Exhaust Pipes

- YSS Top Line rear shocks

- YSS fork upgrade kit

- Motone Customs Up and Over Risers

- Domino XM2 Throttle

- Brembo RCS15 / with TWM clutch

- Brembo SA Sinter Pads Front

Venhill Featherlight Clutch:

Other Mods:
- LSL SuperbikeBars
- Big Port Grips
- Highsider Montana Mirrors
- BAAK Side Pannels
- BAAK Tank Pads
- Motogadget MoBlaze LED Indicators (front and rear)
- BAAK Rear Indicator brackets
- BAAK front Indicator brackets
- Motone Customs Headlight Bracket
- Tec Bike Parts Rear Pegs
- Tec Bike Parts Chain Guard
- Tec Bike Parts Bash Plate
- Domino Switch Gear

Future mods in the pipeline include
- New tires (TBD)
- 4 Piston Calipers (TBD)
- LED headlight bulb

[masterofnonetv]

Always make sure the barrel can turn freely when its put into the slot of the throttle because if it binds and bends the cable with every turn of the throttle it will cause the cable to fray and eventually break, learned this the hard way!😂🍻

[Gambo]

Great technical info and a nice job done there WM.
I used a near identical process back in the day when I worked in a bike number of clutch cables I repaired was countless. We used to call the fraying of the cable end a bird's nest rather than a bird's cage, but the technique was the same.

[sportytoes]

Research this after having to pay $195 to motiopro for a custom cable for an xr100. I tried making a cable before using a torch and fried the cable. Since i ride crap bikes often the investment in a solder pot and the right materials seems wise long term. I have a bunch of bikes. Between throttles, clutches and multiple bikes, i need to master this. Thanks for making this approachable for me. Less $ and less downtime in the future.

[fabianherrera]

Great video, can really tell you took the time to research and also ask around, thanks for solder explanation as i couldnt get a straight answer online, a lot of people said that high silver content was the way to go because lead was too soft, idk. Appreciate it man!

[niconine]

Yea man proper pro class. This vid will be my go to for any future cable changes & upgrades

[zombiewoof]

Excellent explanation! Made a throttle cable last week and came out perfect, very strong connection of the brass barrel.

[strubbleler]

Awesome! I tried it today with copper flux and a random cable + a blowtorch and… after 4 tries… i gave up, the solder would never stick!… but after watching this, i see i have to do some more research

[mudslingerm]

Thanks for this video, Perfect explanation!

[Mickey-uybg]

Thanks Mate, great info would like to know how to obtain the products I will need to do my own cable's. I'm in the USA need a link to the place that has the material for all that. Have a great day 👍😊

[rajlucka]

Nice video!
Good to see you experimenting with the intro.

[samus]

I've swapped a Ninja front end onto a bmw airhead and have to make up a split cable. This is good help.

[blazesboylan]

I do some occasional soldering but I’d never seen a soldering pot until I watched this video. An hour later I got an email from Revival Cycles pitching their new control cable dip soldering system. Apparently my home workshop is woefully incomplete, though I have to wonder how many times I’d use it. Until you post a video showing what else one can do with a soldering pot (lead fondu?) I may have to go without.

[LocalAutist]

Will definitely try this out on my custom built bike as the stock cable is too long and barely holding togetjer anyways 😛

[georgesaint]

Well done great video, you have explained this all very well. I look forward to your videos.

[DormanDiaries]

Nice vid, I keep meaning to do mine as need longer (currently routed around back of forks). We did all cables on my wife’s Kawasaki this way using venhill kits. They are very good. I used a brass stop end and a candle for the solder pot. Worst part is the bird-caging without a tool I found.

[dalewintle]

Nice vid J quality work there 👌 bit faffy for me tbf but you never know 🤷‍♂️ keep up the great content bud 👍🏻

[stevesanelli]

Great result & clever to do a test piece 👌

[daveinwla]

Kinga Tanajewska of "On Her Bike, Episode 90" had the front rim of her GS sealed to run the tire tubeless.
There's been no word on the result, but her opinion about it might be helpful for doing the same on the RE Interceptor.

[edwardspan]

Nice. Now I know how they put the ends on all the bike cables I have bought over the years.

[rcr]

Perfect! This is exactly the mod I have been looking for to do. Super appreciate you taking the time to create and share the content.

For the ends of the cable that meet the throttle housing - which hardware did you end up using? e.g. did you use the stock RE cable adjusters and ends or did you assemble it from the venhill kit?