Cables
By Scott Holton, J&P Tech

This is a follow up on our last topic of discussion, handlebars. Cables and Brake lines are very confusing and we are going to try to clear up some of the mystery.

We will start with throttle cables. In the modern Era (1980 to 2003) we use a two cable system. This has been mandated by the government to preclude sticking throttles. In case the throttle does stick, the two cable system has a positive action when the handgrip is closed, closing the throttle. Through the years we have had three types of cables. The first was used on "butterfly" type Keihin carbs that were used on Big Twins 1976 to 89 and XL's 1976 to 1986. The second was used on "CV" style Keihin carbs on Big Twins 1990 to 1995 and XL's 1987 to 1995. The third type was used 1996 to 2003 on all models.

First let me explain the differences. All cables in our catalog are given in cable housing length. The difference in the butterfly Keihin cables to the CV Keihin cables is the internal wire length. The later style cables have the longer wire. On both types of cables there is a threaded portion that screws into the switch housing. Pull cables (throttle) have different thread diameters than Push (idle) cables so they cannot be installed incorrectly. Another identifying feature of an idle cable is a 1/4 inch long spring at the bottom of the cable. 1996 and up are no longer threaded and use a clip to hold the cable in place. Wire length & different diameters are the same 1996 and up.

Who cares? Why do we need to know this? One of the most popular modifications today's biker undertakes is converting to the S&S carb. When this carb was designed the butterfly Keihin was in use, so the designers at S&S set their carb up to take the stock cables of the era. This was fine until 1987 on XL's and 1990 on Big Twins when the carb changed. The cables used on the CV were not compatible with the S&S. Because of the way the cables screwed into the switch housing the easy solution was to retro-fit the stock butterfly Keihin cables to the later model bike. 1996 threw a curve into the works since there were no stock cables that could clip in with proper wire length to use with the S&S. The aftermarket was quick to jump in with special cables for this application. These special cables worked just fine. But in 1999 S&S redesigned the cable bracket on the carb to allow the use of the "CV" type cables with their wonderful carb. Now there are a ton of carbs out there that do not have this updated bracket that can still work on later model bikes if this unit is installed. The S&S (J&P) Part Number for this updated bracket is 11- 2338. The biggest identifying feature is that the early bracket has the tubes for the cables relatively flat while the late bracket has the tubes raised about an inch.

The next thing for us to tackle is brake hoses. We have a very neat modular system in our 2002 catalog on page 508. Using the system correctly can bring highly satisfactory results. The hardest thing to understand is what fittings to use with the universal hoses. There are 2 different size fittings used from 1984 to 2003, 10 mm and 12 mm. A 10 mm banjo fitting will have an inside diameter of .400. A 12 mm banjo fitting will have an inside diameter of .480. Most stock brake calipers 1984 - 2003 are 10 mm except Springer Softails® and FXD Super Glides which are 12 mm. All the aftermarket brakes I've seen are 10 mm. I would like to point out I have not seen every aftermarket brake available, so its possible there may be a 12 mm style out there (but I have not seen it). Most of the stock master cylinders are 12 mm type with the exceptions again being the Springer Softails® and FXD Super Glides. 1972 to 1981 uses 3/8 inverted flare, as do the earlier calipers. When you look in the hole on one of these types you see a cone pointing up at you. If you don't see the cone, it is the banjo type. We have various different bends on these fittings to give us whatever look we want. On the other end of each of these is a male AN-3 fitting that the universal line attaches to. All in all, a very easy way to develop whatever custom line is required.

This will be a good stopping point for this month with the final installment coming in the next Express. 11-2338