Control Cables Part 3

The front brake cable was definitely not original. It appeared to be some kind of universal replacement because there was no yoke fitting at the brake end--only a clamp arrangement that allowed adjusting the inner wire length.

Here is the handlebar end with the barrel that slips into the brake lever, and the front brakelight switch. The switch apparently works by compressing a rubber washer enough for some contacts to touch. I thought it was bad at first, but just wasn't using enough force.

I made a yoke for the brake end, starting from a hunk of 1/2" key stock.

The new yoke will provide another place to adjust the brake control. I zinc plated the steel parts for some weather resistace. I know I've got some 1/4" clevis pins around, but after looking for half an hour, it seemed quicker to just make one.

Cleaned up and replated the clutch and brake adjusters at the levers.

New brake cable installed. Since I didn't have an old original cable to get accurate measurements from, I had to guess at the length of the inner wire. When I installed it, it took up all of the adjustment capacity both at the yoke and at the hand lever to get it close. I'll have to take it apart and shorten the wire by a little over an inch. The wire ends can be unsoldered and re-used, so it's not a huge deal.

The materials for the five control cables cost probably less than a third of the cost of new cables, plus maybe a day of my time. Being pleasant work, I consider that a good deal.