Cable Routing

[Keithuu]

Now that I've had a chance to log a few hours on my '75 250, I find that there may be a problem with the clutch cable routing. Currently, the cable runs behind the headlight, makes a turn between the right side fork tube and frame, runs along between the frame and tank, crosses thru the frame just ahead of the coil, lays across the top of the left side horizontal frame tube, then heads down thru the loop on the motor support and over to the right side case mount - WHEW!!

The problem appears to be that the cable is trapped between the frame and tank and also along the frame tube. Rub marks are apparent and that can't be a good thing. This "trapping" results in the cable only flexing within the last foot or so, the length of it between the perch and where it contacts the frame next to the steering head.

Is the loop on the frame supposed to be used for cable routing? It certainly seems so but with the cable being trapped, a potential kink point is created.

I've thought about creating more cable clearance on the right side frame gusset (with a 4 lb. hammer or equivalent!) but I'd still be faced with the fact that the cable is trapped on the left frame tube by the tank. If I try to route the cable under the left frame tube, it makes for a rather abrupt curve befor the brace loop.

Something's not right here - HELP!

Keithuu

[slvrbrdfxr]

Keith,
My bike is routed through the loop on the left side of the steering head and then between the left side of the frame and gas tank to the left engine support brace and then under the carb. Not sure if this is correct but seems to work fine for me. Others on the board can probably let us know for sure.
Dave McCullough

[Doug Wilford]

The frame loops were for the tank straps not cables.

[454MRW]

Thanks to pics sent to me by Freddie Smith of his origninal bikes wiring and cable routing, I actually remember that the clutch cable on my 74 250 Harecsrambler came out of the opening where the cable end goes to the cluch actuator and winds clockwise around the engine at the base of the cylinder and then goes upward just inside of the left front frame tube and is secured to the left tube just above the exhaust mount and then continues across the left side of the steering head and through the left side ring. This is on an unaltered 1977 GS6. I am sure that Freddie would gladly share his pics with the group. It would be great to have some of them posted for reference. Mike
I found his link:
http://www.villagephotos.com/pubbrowse.asp?folder_id=1655017

Michael R. Winter
1974 250 Harescrambler
1975 250 HS Project
1977 250 MC5 Project
1978 250 MX6  
1979 250 KTM Project
1980 250 MX KTM

[Chakka]

Thanks for posting those Michael. Next on my restore list is a 77' 250 and those pictures are fantastic for reference!

Chris

[454MRW]

Keithuu,
I just started working on a 1974 1/2 (411) 250 with a 175 engine in it and found the same cable routing as you mentioned. It has a small diameter clutch cable and may be the original one which is routed just under the tank side bumper on the left side of the steering head gusset and through the ring as well. The cable is smaller diameter than the tank bumper thickness, so it should not bind between the tank and the frame. As the cable runs rearward from the tank bumper, it goes through the rear strap of the coil mud shield and down through the ring in the engine support brace also. I took a few pics of the cable routing and can email you them if you would like. Mike [email protected]

Michael R. Winter
1974 250 Harescrambler
1975 250 HS Project
1977 250 MC5 Project
1978 250 MX6  
1979 250 KTM Project
1980 250 MX KTM

[Keithuu]

Thanks for all the tips. It sure sounds like the "lefterly" routing is the way to go and I'll give it a try. I forgot to mention that I'm using a Terrycable, not N.O.S., so I can't be 100% sure the length and thickness are the same as original.

Right now, the throttle cable is routed thru the left loop and seems to work fine without kinks or binding, but then it's a lot thinner than the chubby clutch cable.

Michael, I would indeed like to see your pics if you'd e-mail 'em:D

Keithuu

[454MRW]

Keithuu,
You have mail! Mike

Michael R. Winter
1974 250 Harescrambler
1974 1/2 250/175
1975 250 HS Project
1977 250 MC5 Project
1978 250 MX6  
1979 250 KTM Project
1980 250 MX KTM

[fasmith]

Mike,  

If you need more pictures, just let me know.  

The old girl is coming along...  just more time and elbow grease.

Freddie

[Keithuu]

Between the tips and the photos sent by Michael, I think I've got it right. The clutch cable now runs along the left side of the frame, through the loop, above the tank bumper, and down thru the brace loop. Works great, no kinks, and even seems to pull easier.

I switched the throttle cable to the right side, again thru the loop, and above the tank bumper. Once I got the relationship between the clutch, throttle, and brake cables sorted out behind the headlight, all seems hunky dory.

In deference to Doug, I was able to utilize the loops for the cables since I'm using a strap on the tank, not the cable retainers, so there's plenty of room. []

Keithuu

[Mike Lenz]

You will find that with the under the cylinder cable routing the cable is almost too short.  I have told this to Alan Buehner so maybe he has fixed it or will be.