Author Topic: Throttle/Clutch Cable Lengths  (Read 1212 times)

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Offline papi_sosaa

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Throttle/Clutch Cable Lengths
« on: May 13, 2025, 06:27:13 AM »
I'm trying to get some shorter cables for my CB650 cafe project but I'm having a hard time finding a decent replacement set.

The factory handlebars are high up and that means the OEM cables are too long. Has anybody replaced their bars with either fork clip-ons, a clubman bar, or anything that would lower the controls and shortens cable lengths. If so, which cables did you use?

If you made your own cables, did you buy a cable to use as the base and then modified it from there?

Please see the measurements below:

CB650SC Stock
Motion Pro Item-ID’s


Throttle - Pull (02-0018):
  • 48 1/2” total length
  • 43 5/8” inner housing
  • 4 3/8” slack
  • Too long, perfect slack

Throttle - Push (02-0019):
  • 48” total length
  • 43 3/8” inner housing
  • 4 1/2” slack
  • Too long, perfect slack

Clutch Cable (03-0109):
  • 54 3/4” total length
  • 2 1/2” slack
  • Too long, perfect slack?


Others I've tried

Short Clutch Cable (02-0124):
  • 50” total length
  • 46 7/8” inner housing
  • 3 1/8” slack
  • Slightly long, not enough slack??
  • 2 1/2 vs 3 1/8”??

Throttle - Pull (02-0007):
  • 40 1/4” total length
  • 36.5” inner housing
  • 3 3/4” slack
  • Perfect length, not enough slack

Throttle - Push (02-0008):
  • 39 3/4” total length
  • 36” inner housing
  • 3 3/4” slack
  • Perfect length, not enough slack


Going to try

Short CB750F/K CB550K cables (4into1):

Throttle - Pull
  • 40 3/8” total length
  • 34 3/4” inner housing
  • 5 3/8” slack

Throttle - Push
  • 39 1/4” total length
  • 35 1/2” inner housing
  • 3 1/2” slack

Clutch Cable
  • 48 3/4” total length
  • 45” inner housing (including threaded adjuster)
  • 43 5/8” inner housing (not including threaded adjuster)
  • 3 1/8” slack
1982 Honda CB650SC Nighthawk Cafe Racer

Offline Don R

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Re: Throttle/Clutch Cable Lengths
« Reply #1 on: May 13, 2025, 10:03:40 AM »
 If I recall correctly the later bikes with the PD carbs have a longer cable on the pull side. I got a set by accident once when I didn't pay enough attention. That might be the one with 5 3/8" slack.
 We should have a chart somewhere with what cables fit with different bikes/handlebars.
 I have a set of early 750 4 X 1 cable carbs with the single cable side extra long. I kept it for parts but it could possibly be shortened. It appears that motion pro has tools for that purpose.
« Last Edit: May 13, 2025, 10:07:21 AM by Don R »
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Offline Bodi

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Re: Throttle/Clutch Cable Lengths
« Reply #2 on: May 15, 2025, 10:40:33 AM »
Obviously - I hope it's obvious - you can't lengthen cables.
Shortening is relatively easy. A new one to shorten is best, as lube makes attaching a new barrel nipple (or other end fitting) more difficult.

You need a pretty hot torch and some silver solder plus its special flux. Normal solder is too soft and the end can pull off, don't trust it. Silver solder is strong but needs a higher temperature than a propane torch produces. Maybe MAPP but I haven't tried it. Silver solder is expensive... (duh, silver) but jewelry places may sell you just an inch or two, and give you a dab of flux.
If the existing nipple is soldered on, heat it up and pull it off. Remove the solder from the hole by heating it up and smacking it against a hard thing so the liquid metal shoots out.
The ferrule on the sleeve can be tough to remove, heating it and pulling works. You probably have to enlarge it to fit on again.
Pull the core back and cut the sleeve to the length you want. A super fine hacksaw is ok, cutting pliers will just make a mess with the spiral steel all screwed up. You can use a grinder but the plastic is going to melt.
Get the ferrule back on, it is important. If it's loose, either accept that or use some glue. If it goes in a typical holder, being loose doesn't much matter.
Push the core through and mark where you want the nipple.
(If you had to cut the original off, there are nipple and ferrule kits you can buy. The setscrew emergency nipples are just that: they will come loose or pop off when most inconvenient OK - to get home but replace or repair the cable properly.)
Once marked, put a small dab of flux where you want the nipple. Heat up and tin the cable with the silver solder, use as little as possible avoiding having solder wick in very far away.
Reused nipples already have a coating of the solder. New ones, smear some flux in the hole and on the tinned spot on the cable. Thread the core through and position it where you tinned. Heat it up and touch the solder right at the hole. You can see when it wicks in, if it doesn't then likely it isn't hot enough. That's it, let it cool naturally then clean off excess flux with solvent. Gasoline should work. Then cut off the protruding core. File or grind off the stub if it can poke anyone once mounted, the cut off end is sharp.
A used cable will probably be saturated with lube. Clean where you want the nipple as well as possible with a really good solvent, a few inches either way. Acetone is probably one of the best for this. You want the strands clean inside, as the solder should stick them all together as well as to the nipple. Even a new cable should be cleaned with acetone before soldering.

Offline papi_sosaa

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Re: Throttle/Clutch Cable Lengths
« Reply #3 on: May 22, 2025, 10:14:24 AM »
To add my update to this.

I took the clutch cable (03-0109), shortened it on the lever side, re-soldered the ferrule, and it is good for the most part however it's about 1-1.5" too short for full right lock. At full right lock it's hugging the frame pretty tightly and tugging on the perch adjustment knob. Luckily, I purchased a second clutch cable in case I messed up the first one so I'm going to shorten it but make it about 1.5-2" longer then my last cable and repeat the process again.

Trial and error ;D

As for the throttle cables, I'm having somewhat better luck with the 02-0100 and 02-0101 cables. They're meant for an 83-85' CB650SC but they meet my cable length requirement. Only downside is that I find the cable slack is about 1/16 to 1/8 too short and it's causing the carbs to bind up a bit. The pull cable is fine as long as I position both locking nuts on the bottom of the bracket on the carb side. If I don't use the push cable then the throttle will snap shut like it's supposed to in both steering lock-to-lock positions. Weirdly enough, the throttle closes "okay" when the push cable is mounted and the wheel is full left lock but then requires my intervention if it's full right lock. To remedy this, I'm going to shave down the push cable holder on the bracket by about 1/16 to 1/8 of an inch so that I can recover that loss of slack.

Based on my picture, that is the height that the push cable would need to sit at in order to allow the throttle to snap shut when released in full steering lock-to-lock.

Cable Dimensions:

Clutch Cable (Motion Pro 03-0109):
1982 Honda CB650SC Equivalent
  • 54 3/4” total length
  • 2 1/2” slack
  • Shortened the cable, will measure when I remake it
Throttle - Pull (Motion Pro 02-0018):
1982 Honda CB650SC Equivalent
  • 48 1/2” total length
  • 43 5/8” inner housing
  • 4 3/8” slack***
Throttle - Push (Motion Pro 02-0019):
1982 Honda CB650SC Equivalent
  • 48” total length
  • 43 3/8” inner housing
  • 4 1/2” slack***

New Throttle Cables
Throttle - Pull (Motion Pro 02-0100):
1983 Honda CB650SC Equivalent
  • 40 1/4” total length
  • 4 1/8” slack***
Throttle - Push (Motion Pro 02-0101):
1984-1985 Honda CB650SC Equivalent
  • 40 7/8” total length
  • 4 1/8” slack***
« Last Edit: May 22, 2025, 10:21:57 AM by papi_sosaa »
1982 Honda CB650SC Nighthawk Cafe Racer

Offline papi_sosaa

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Re: Throttle/Clutch Cable Lengths
« Reply #4 on: May 27, 2025, 07:25:06 AM »
I managed to get the push/pull cables working properly from steering lock-to-lock. I ended up shaving down the push cable bracket a bit and that resolved the issue.
« Last Edit: May 27, 2025, 07:29:15 AM by papi_sosaa »
1982 Honda CB650SC Nighthawk Cafe Racer

Offline Acidbass32

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Re: Throttle/Clutch Cable Lengths
« Reply #5 on: October 15, 2025, 11:50:21 AM »
What bars and front end do you have? Encountering a similar issue with my cafe build. 71 cb500 frame, 77cb550 engine, 01 R6 front end. Noticed the stock throttle cables and clutch cables all seem too long with my clip ons and really debating just making a set cables of my own.

Offline kerryb

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Re: Throttle/Clutch Cable Lengths
« Reply #6 on: October 15, 2025, 09:22:02 PM »
I used the clutch cable from my ‘78 cb750k for the 82 cb650sc with clip-ons.  An ‘83 goldwing clutch perch (w/choke) put the clutch cable right where I needed it.
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Offline papi_sosaa

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Re: Throttle/Clutch Cable Lengths
« Reply #7 on: October 17, 2025, 07:35:38 AM »
What bars and front end do you have? Encountering a similar issue with my cafe build. 71 cb500 frame, 77cb550 engine, 01 R6 front end. Noticed the stock throttle cables and clutch cables all seem too long with my clip ons and really debating just making a set cables of my own.

I used clip-ons from Amazon.

Originally the choke and clutch were in the same perch but I've moved the choke to the top triple tree and used the Motion Pro 02-0157 choke lever. As for the clutch cable, I completely forgot to measure it but it's the OEM clutch cable for the 1982 CB650SC that I had shortened and I believe the clutch perch I'm using is off of a 79-80 CB650. I've been using Motion Pro 02-0100 and Motion Pro 02-0101 throttle cables with the shaved down carburetor cable bracket.

I adjusted the clutch cable last month as there was more than normal play in the clutch lever but overall, I've been fine all summer.
1982 Honda CB650SC Nighthawk Cafe Racer