THE THROTTLE CABLE

Whilst checking through the control cables I discovered that I was short of a throttle cable.  You might have thought that it would have been very obvious but as I said non of the cables were identified and none were terminated.  I guess I was bewitched by their nice shiny grey covers.

I got on to my new found friends at Cassa Lambretta, Danny (the LD expert) and Lee.  In no time at all I had a new throttle cable for only £2.50 plus P&P - bargain.  I also took the opportunity to buy two trunnions for the ends of the gear change cables (£2.08). I wonder where those bit went and why they were lost.

This nipple should be rotated by 90 degrees

I ran the cable through the frame on the correct rout.  My first problem was that when came to fit throttle end I had difficulty in getting the nipple to sit nicely in the twist grip.  No matter what I did the nipple always wanted to be at right angles to the recess in the twist griip.  I tried twisting the nipple to the position I wanted but it only sprung back the its original position.  If I tried to twist the nipple further, say through 120 degrees, the nipple would jump 180 degrees and so I was back in the same position.  I think there must be something wrong with the inner itself, a kink?

12 mm short

Having finally got the cable into the twist grip with the nipple sitting correctly in its recess and the assembly clamped tight on the handlebar I turned my attention to the other end.  Oh dear, it looks a bit short. (perhaps I said something a  little stronger than that)

I re checked everything  but the inner cable was still short.  Having slept on it I had two options, buy a new able or shorten the outer sheath.  I think the first was the best option because it might clear the nipple problem but I felt I could wait until I sent my next order to Danny.  In the mean time I would just have to shorten the outer by 12mm.  Easier said than done.

Firstly the end ferrel had to be removed.  This is swagged onto the end of the cable and can't just be pulled off.  By carefully cutting round the ferrel (using a junior hacksaw) above the swagging it was possible to remove it and cut through the swagged bit to remove that.  

Now for the outer.  Because both ends have crimped ends it is not possible to remove the inner cable.  This means that when cutting through the outer you have to be careful not to cut the inner cable.  By using the hacksaw again and carefully working my way round the outer progressively cutting into the wrapped steel outer it was possible to separate the end 12mm.  Now it only remained to cut off this short length, again without damaging the inner cable.  By holding the short length in a vice it was possible to cut along its length and finally produce a series of rings that then could be removed.  The inner low friction sheath was easy to remove with a knife.  With the outer/inner cable shortened I was able to glue the end ferrel back over the end of the outer sheath.  Job done, almost.

The cable fitted as I think it should and the carb throttle leaver operates with the with the twist grip.  BUT .....
I'm still not happy with the twist grip end nipple.  It was difficult to assemble and I think that because it is constantly trying to twist 90 degrees it will eventually do and then there is a change of failure.  Knowing my luck that will be at some most inconvenient moment.  I had a try at unsoldering the nipple before I realised that it was crimped onto the end of the cable.  In my day they were always soldered and I could have rectified the problem.  I will have a talk with Danny before ordering another cable.  I think it essential that the twist grip end nipple sits correctly and the length is right.

And now for the gear change cables.

CONTROL CABLES

When I bought the scooter the advert said that it had been fitted with "quality frictionless cables".  As the blog so far has indicated I've not been too interested in controlling anything.  Whilst waiting for a resolution on the kick start problem I thought it might be an idea to check out just what I had got with regard to control cables.

The cables had been tied onto the frame and run between the handle bars and the engine area.  Their function was not identified.  My first difficulty was to sort out what happened at the handlebars.  Referring to the limited number of pictures of the LD I found that the routing seemed to vary.  Sometimes the cables were run in front of the handle bars and sometimes behind.  I settled for the clutch and brake to run in front, the gear change and throttle behind.

 These pictures show one version of the routing.  From the other pictures I have seen I think it's more common for the break and clutch cables to cross over and thus avoid the sharp bend where they exit the leg shield.  

I don't have all the plastic sleeves so I have only fitted the pieces where the cables exit the leg shield.  I will eventually have to sort this out but my priority is still to get the scooter running.


 Thinking that he brakes would be a good place to start I worked on the rear first.  This avoided any involvement with the handlebars and so no dilemma.  Having purchased the necessary missing clamps etc I was able to connect both ends of the cable.  Once done I now had a rear brake - progress.

I had a small problem with fitting the nipple into the break leaver.  The slot for the cable was too tight to allow the cable to pass.  I think it was damage and not that the cable was thicker than normal.  A little filing soon sorted the problem.  I have to say that who ever made the pins for the brake leaver got the screw driver slots far too narrow.  I will have to make a special screw driver to fit so at the moment they are tight enough for testing but will need seeing to before a road test.  Will I remember?  

 Now for the throttle cable.  

THE KICK START START?

You may remember that I was having problems with replacing my kick start shaft.  Eventually on the 28/02/12 I sent the complete unit to Scooter Surgery for Patrick to investigate why I was having a problem.  On Saturday 28th April I received it back.  I think that it is chiefly due to Maude being on my case that it has finally came to the top of Patrick's pile.

I rushed down to the garage and found the kick start leaver, had the problem been solved?  I guess the immediate answer is NO. 

 

The leaver fits on the shaft as I would have expected but when I come to fit the clamp bolt the groove in the shaft does not line up with the the bolt in the leaver.  Disappointment hardly describes my feelings at the moment because this is where I had started.






Maude replied to my email saying that Patrick had fitted his LD leaver to the unit and all had been well.  The suggestion now is for me to take the scooter down to Hammersmith for Patrick to sort it out.  I'm not sure my pension would support that.  I have said that I need some time to investigate before making a decision on my next move.

Some good news, Patrick has not charged me for the time he has spent investigating, possibly encouraged by Maude.  I'm grateful and I don't want to fall out with them.  I look forward to taking the mechanism apart again and seeing what mods, if any, were made to the shaft.