Introduction: Changing a Moped Brake Cable!

Cables stretch, break, corrode and sometimes, just get ugly.  They're cheap and easy to change, and you gotta love that smooth feel. It's nice. I'm working on a Puch Magnum, but it's pretty much the same for most mopeds. Check it, yo....

FYI, BTW......

I made it at Techshop. They have a work bay where you can work on your car, motorcycle, moped... whatever! There are 3 of them around the SF Bay Area, so it's pretty convenient. There's others around the country and they have lots of tools and workshops. Wood, Metal, Fabrics, Electronics and more. It's rad.

Check it out here:                                www.techshop.ws

Step 1: Taco's or Burrito's?!?

I like taco's AND burrito's. It's a tuff decision.....

I didn't take any pictures of cable removal, because I'm dumb. I'm going to walk you through how to install a new cable and hopefully it will become obvious how to remove your old cable. My apologies...

I start by routing the new cable neatly. Most forks will have a cable stay to run the cable through. While you're removing the old cable, check to see how it's routed. If it's neat and proper, great. run the new cable the same way. If the old cable is dangling in the wind, spend some time to figure out the cleanest way to run your new cable. If the cable seems too long, it may require cutting the cable and housing and using a cable knarp.


Step 2: Next!

The new cable will most likely have a cable tensioner at one or both ends. Mine has (2) M6 10mm nuts to lock it onto place. You'll need to unscrew one of the nuts, then slip the cable through the gap on the mounting point and drop in the tensioner. Now, screw the nut back onto the bottom. We'll tighten those down later...

Next, pull in the brake lever and hook the cable end around/through the brake lever....

At the opposite end of the cable, take the cable holder out of the brake handle lever. This will fit around the other cable and and hold the cable in place...

It was hard to get a good picture here. Just push the cable into the brake handle lever and drop in the cable holder through the hole, and around the cable.

The cable tensioner on this end will slide neatly into the handle control.


Step 3: Adjust.

There are 2 adjustment points on this cable. I like to adjust the bottom one first. It makes it easy if you first push up on the brake lever and adjust with your fingers. Once you have good cable tension, lock down the 2 nuts.

I like my cable tension hair trigger. Others like it slacky and relaxed. My recommendation would be to tension the front and rear the same. That's sexy.

well, that about wraps it up for this Instructable. It's not my best, I know. Hopefully this will give you some helpful information, whilst you replace your cables.


Best of luck!

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