Brake and Throttle Cables

[Mike Bean]

The cheapest brake and throttle cables I could come up with, was to go to Wal-Mart and purchase two sets of the universal brake kits for bikes. They cost about $4.99 ea. and are they same thing you will get online.

You will usually use the longest cable supplied in each kits and cut to your needs. For the cable ends I drilled out a bolt and used a nut to lock the end for the brake caliper and I drilled out a very small screw and used it on the throttle linkage of the motor.
:shock:

[rino]

I to use bike cables but soder brass cable ends to it just adds a pro look.

[SupraLuda]

To top that... get a "crotch rocket" style motorcycle hydraulic brake (or clutch for that matter) setup. All you need it the handle itself and the canister dealy (master I think they call it), run some line down to your disc and your set!

Dump your manualsystem for a cheap, stop assured brake system.

[RUBICON]

There are a couple of items that are available from motorcycle grave yards that I found usefull and the price was right. I must say that walking through the piles of twisted sportbikes was chilling. I wrenched bikes for a living when I was young and I know a lot of these riders never lived through the impact.

Throttles are available in twist grip and thumb type. The twist type are high quality but the short stroke of the carb linkage must be modified to decrease the sensitivity of them. The cables are nylon lined and silky smooth. The thumb throttles are found on ATV's and work fine also.

If you have handlebars and hydraulic brakes the motorcycle front brake master cylinder works great. Get the hose and banjo bolts ( metric ) so you can fabricate a adapter block to transition to kart type brake line fittings ( 1/8 npt ).

All motorcycle shops have cable jackets, cables, ends, in-line adjusters and solder on end fittings to make your own.

[Dirtsurfer]

We used a steering wheel from a honda odyssey (FL250) and steering stem. It has finger controls for the gas and brake. The Brake on ours is just a band brake, so we didn't need any master cylinder stuff. Throttle cable is the Wal-mart brake cable, too.

[tomwoh]

Can you post pictures of how your attached at both ends and holding the cable?

[Canadiankid]

I used a 8" grant steering wheel & went down to my local small engine repair place and searched his pile of weed wackers for the throttle control I wanted that would work and had a kill switch ($5). Then off to the bicycle shop to get a cable, sleave & ends ($5). Put a return spring over the motor end of the cable, wired in the kill switch and the whole thing works great.

[josullivan]

I have had my BSR "finished" for a while now... While building, I found it hard on the wallet to buy the parts I really wanted. I basically screwed the whole project by building my own stool instead of modifying my motor to make everything "fit" under the store bought stool... As I look at it though, I see the way I should have done it, so i'm going back and buying the right parts one at a time in order to get er done just right. I originally robbed the brake levers and cables from an old mountain bike to use for throttle control and brakes. This setup was akward to say the least... And for my girlfriend... Almost deadly!!! I finally got my hands on a thumb throttle off of a Honda Rancher 4-wheeler. This thing works GREAT!!! I will be singing the praises of the thumb throttle till i'm blue in the face...
I have put several miles on my stool by now... been pulled over by the police twice, and still can't get enough!!!:cheers:

[voodoo_stepchild]

I went to rocky mountain atv and mc and bought all new for motorcross. It wasnt as expensive as you would think and I got cool looking billet stuff. Handlebars for a 2005 kx250, msr low rise, black 17.00, pro motion complete throttle assembly(twist grip) for 2005 kx 21.00, green and black grips gel type 8.00, pro motion billet clutch perch and lever (quick adjust type) 19.00, pro motion clutch cable (for brake) 13.00. Maybe more than most would like to spend but I had 7 of these things to build and I didnt wanna screw around with 7 different throttles, brakes, etc etc etc. Give a swing by there and the staf is real knowledgable if you need a specific size cable or length they can help you out. I just called and said I need this this and this and BAM!!!!!!! on my doorstep in 3 days.

www.rockymountainatvmc.com (http://www.rockymountainatvmc.com)

Voodoo

[SupraLuda]

I went with a snowmobile master setup... fairly easy to find. Easy install too - just connect the brake line to the caliper and its a done deal.

http://img503.imageshack.us/img503/2757/img0918oj9.jpg

In terms of cost for my setup... maybe $100:

1. 10' of 3/16 hydraulic line - $1.25 per foot
2. MPC caliper - $55 shipped on eBay
3. 6" disk/hub - $25 shipped on eBay
4. Brake master - maybe $10 ?? , is a used unit

HTH,
Patrick

[Frank McGrath]

I have to come up with a bracket for the caliper. Any Ideas?
Frank

[Frank McGrath]

I am using braided cable for my throttle and needed a way to fasten the cable to the throttle arm. I found a kit that will mount the cable to the arm.

Kohler part no. 48 755 10-S Kilt, Clamp. Will fit in the hole on the clone 6.5 hp Harbor Freight engine"s throttle arm. Better than buying the Honda kt for 35.00.

I'm almost ready to fire it up.

Frank

[Hotelcalif]

I have to come up with a bracket for the caliper. Any Ideas?
Frank
I cut one off a old racer kart but a flat piece of steel should do the trick.

[KiwiMike]

Smokin Joe, an Ebay seller has all the throttle linkage kits for the Briggs race engines, (Raptor, Animal, Intek, and World Formula).
Some kits include all the brackets and tube to run the cable through.
I buy a lot of stuff through him, he is good to deal with.

[TAIL GATOR]

What is the best method too cut outter cable housing??? Can I reuse the little chrome/metal end caps?? My problem, small ball on one end (mikuni carb) the other end barrel (twist grip). After installing barrel end (1st) on twist grip now I don't have enuff cable left too install on mikuni plunger. :cussing:

[KiwiMike]

The best way to cut the outer cable is to use an air cut-off wheel or a Dremel. A pair of side cutters just won't do it, as it will squash the outer cable.
As for the inner cable, go to Comet and order a new inner cable with the ball end and buy the barrel end for your twist grip. You can buy the ferrels to go over the ends of the outer cable.

http://cometkartsales.com/store/engine/throttle.htm