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US Flag Wednesday, October 23, 2019
Welcome to the British Motorcycle Cable Helper
We usually make our own cables, especially carb cables. We accidentally deleted our notes for making them so as we figure them out again, we will put the specifications here. Terms:
  • Cable - A inner cable and any outer jackets. Could be a single outer jacket, two outer jackets with an adjuster between, etc.
  • Stickout - pull the inner cable to one end and measure from the end of the outer jacket to the finished end of the inner cable.
  • Outer Length - each segment of a cable has an outer jacket. This is the finished length of the outer jacket section.
  • Overall length - Some cables have two outer sections and an adjuster between them. This is a finished length of the outer cable with the adjuster at it's minimum length.
  • Notes:
    • This specification assume handlebars that are 39" tip to tip and rise 4". Significantly wider/taller or narrowed/shorter will require cable length differences.
    • In all cases, if an outer includes an inline adjuster, the measurements are taken with the adjuster screwed all the way in.
    • While these are for Norton, the stickouts should be correct for any Amal 30/32mm carbs.  We have a 1970 Triumph Bonneville to do soon so we'll update this page for that when we make those cables.
Norton Commando Air

These cables require:
  • A cable adjuster on the top of the carb
  • A 2-way junction box, 2 cables with 10-5/8” outer length and 4" stickout. These go between the junction box and the air slide in the carb. Both outer jacket ends are simple ferrules.
  • A cable with one 6" outer, one 13-1/4" outer including an inline cable adjuster. This makes a 19-1/4" overall length. The stickout is 3-5/16". All outer jacket ends are simple ferrules. The inner cable end closest to the cable adjuster is the type for the choke lever you have and all other ends are the small 1/8" diameter connectors for Amal cables and junction boxes.
  • I don't like where the cable adjuster ends up with standard cables so I make the short outer 2" and the long outer 17-1/4".  The means that the tank has to comeoff to adjust it, but there's no reason to ajdust once set.  On bikes I; keeping, I simply eliminat ehte choke _ I consider them silly on Amal carbs!
Norton Commando Throttle

These cables require:
  • A cable adjuster on the top of the carb
  • A 2-way junction box, 2 cables with 10-1/2" outer length and 3-3/4" stickout - this puts the carb top adjusters about 1/2 way out so 3-5/8" might be better. These go between the junction box and the throttle valve in the carb. Both outer jacket ends are simple ferrules.
  • A cable with one 6" outer, one 14-1/2" outer, and an an inline cable adjuster. This makes a 21-1/2" overall length; however, I check this before cutting.  These numbers came from two supposedly original cables. All assembled including the junction box makes the outer length 34".  For 33" wide 6" rise bars, 2 to 3" longer would be good. The stickout depends on the twistgrip:
    • Original Amal 364 type: 2-9/16" to 2-11/16". The ones I'm using are 2-9/16" but this puts the cable ajusted in the middle of it's adjustment so the next one I make will be 2-11/16"
    • Wassel "Universal", Part: WW83219 requires 3-1/2"
    All outer jacket ends are simple ferrules. The inner cable end closest to the cable adjuster is the type for the throttle and all other ends are the small 1/8" diameter connectors for Amal cables and junction boxes.
 




Copyright © 2017-2019 Greg Marsh Enterprises
 8116 Arlington Blvd. #171, Falls Church, VA 22042, (703) 200-4025
Burlen, the parent of the AMAL Carb Company    The AMAL Carb Company    Tri-Spark, inovative electrical products for the Vintage British Motorcycle    Wassell, the 70+ year old suppliers of British Motorcycle parts    Central Wheel Company, the 120+ old suppliers of spokes and rims
Copyright © 2003-2019 Greg Marsh Enterprises
 8116 Arlington Blvd. #171, Falls Church, VA 22042, (703) 200-4025