Puch 2.0

I’m happy that I found a decent way to make a new throttle cable end for a dellorto. Here is how the new cable looks.

The smaller end needs to be cut off because the cable is too long to go on this handlebar setup. Once you cut it off, you need to make a new end that fits through all the holes in the carb, but not through the final hole in the throttle slide. That means it really has to be pretty close to the diameter of the factory end.

To make the new end I used the inside or clamping part of a ring connector.

It worked out well. It took me a little while to shape it with my crimpers and side cutters, but it didn’t take very long. I put the end on the cable 2 inches from the end of the casing. That gave me just about the right spacing to slide.

You can solder an end on there, but I didn’t have much luck getting the right shape the last time I tried…AND when I was finished it ended up pulling off inside the carb. That wasn’t cool. I will admit though that my soldering skills are a little on the weak side.

All of the cables are now finished. I’m pretty excited about that. They all feel pretty good too.

After finishing that up, I moved on to the crank. I pulled it off the bike, which wasn’t fun, but I eventually got it with a little bit of elbow grease and some PB Blaster.

I then cut off the crank arm just below the hole for the wedge shaped pin.

I measured the extension I need at 1-1/4″. I hope to find the material tomorrow and get it welded up soon. It may be a few more days before I throw up another update.