Teds new project a CB500 K1 mostly version 0.5 circa 1972.

[Oddjob]

I'd leave the top routing alone but route the cables around the other side of the headstock and through the coil opening Ted. See how that feels. The tighter the bends the worse the throttle feels.

[Laverdaroo]

I was on about air box lids Ken so shove yer bolts


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[McCabe-Thiele (Ted)]

Ted I had mine below the tank mounts on the 550 but they were having a tendency to hook around the lower corner of the fuel tank when manouvering. Definately I would say above the tank mounts can’t drop from there.

Presumably Johnny both your throttle cables were not routed between the forks but to the right side of the frame?

I think that what Ken is suggesting. Do you have any tips regarding the clutch cable route?

At the moment though not connected at the engine end, mine goes from the handlebar lever down the hole in the instrument bracket, crossing to the right side of the frame then crossing to the left side of the frame through the gap at the rear above the coils. Finally dropping down between intakes 1 & 2 so the cable reaches the hole on the left side engine cover.

[Bryanj]

Clutch sounds right from memory Ted, big thing is as straight as possible up from casing adjuster

[McCabe-Thiele (Ted)]

Do you know the correct length of a UK clutch cable Bryan as I suspect mine is for US bars?

The only way I can find to route mine without loads of 'spare cable' is by routing it not through the hole in the instrument bracket but as it was when I originally rode the bike - the cable passes over the speedo going down to the right side of the frame between the forks. This route does mean the clutch cable passes high over the speedo clock. See below photo as it was.

.clutch cable by Macabe Thiele, on Flickr

[Bryanj]

Cant remember Ted think it was a new pattern one

[McCabe-Thiele (Ted)]

I have measured the clutch outer cable from ferrule tip to ferrule tip (excluding the adjusters)  it is 4ft 1/16" so that's a nominal 4 ft - with my cable routed in what looks like the best route (#).

That looks like an excess of six to seven and a half inches of outer cable,

# My route is currentky from the clutch lever down through slot in the instrument bracket coming out on the right side of the frame routing above the tank mount then passing through the far end of the coil gap in the frame down between carbs 1 & 2 and into the left side cover.

[Sesman]

Try this Ted. http://forums.sohc4.net/index.php?topic=139600.0
Appreciate it’s about throttle cables, but includes some clues

[McCabe-Thiele (Ted)]

Try this Ted. http://forums.sohc4.net/index.php?topic=139600.0
Appreciate it’s about throttle cables, but includes some clues

Interesting read Phillip,   some books & owners seem to show/say throttle cable runs down the left side of the frame others the right side.
I am now happy with my throttle cables running down the right side - they no longer stick - it seems the cable curve/run makes for a smooth operation - even if it's not original. I can't test effect of steering as I have no wheels in place atm.

All the things I have read appear to agree that the clutch cable starts on the right side then crosses over at the coils to the left - this looks good to me.
If I route my clutch cable through the instrument bracket I have loads of spare cable looping.
Even if I route it as it was not throught the instruments but between the right side of the forks there is an excess of cable loop.
The clincher will be when I know what the correct clutch cable outer length is excluding the adjuster for a UK 500.

If my cable is correct at 4ft then the route certainly can't be through the instrument bracket - I suspect that is for the higher US bars.

[Oddjob]

A genuine UK clutch cable is 107cm from ferrule to ferrule, or 42" if you prefer.

I don't think it routes through the coil opening Ted, I suspect you are correct in saying through the clock bracket down the right side of the frame but I think it crosses to the left just where the throttle cables join the carbs, just before there where the frame starts to flatten out. It then goes through the carbs between 1 & 2 and into the sprocket cover.

[Oddjob]

I've been looking at pics in the workshop manual Ted, figure 245 shows cable routing for the 500, shows both the clutch AND the throttle cables passing through the speedo bracket, throttle cables then go to the LEFT of the headstock and pass through the coil opening, figure 272 shows them there along with what looks to be the clutch doing the same thing but in reverse. The throttle cables appear to be above the tank mount but I would have thought below before seeing that pic, however they could have moved before the pic was taken and not spotted, I seem to recall putting the tank on and making sure they went under the rubber.

Figure 299 shows the clutch cable passing through 1 & 2 inlet manifold bracket, as does fig 86 and fig 56. In fig 310 you can clearly see both throttle cables to the LEFT of the headstock

[McCabe-Thiele (Ted)]

Hi Ken I have seen that throttle cable route through the instrument bracket to the left side of the frame - even worse imho as it's a tight turn up from the throttle grip down into the instruments then back throught the coils to the carb connection on the right side of the frame.
The carb shaft mechanism sits to the riight of centre so atm I prefer my route even if its wrong.

Thanks for the info on the clutch cable being 42" mine is aftermarket - I will see what the clutch cable looks like if not routed through the coil hole.  Most of the manual photos seem to show it going through the coil hole area - that's how mine was routed but not through the instrument bracket.

Advantage of the clutch cable going through the coil hole is it drops at a nice non binding looking angle between the carbs to the left housing.

Oh what fun.

[Oddjob]

There's something wrong Ted IF the throttle cables are having tight turns when routed correctly. They should exit the right hand switchgear pointing almost straight along the bars, not pointing forward so much. This then points them toward the hole in the speedo bracket. Are they like that?

[McCabe-Thiele (Ted)]

There's something wrong Ted IF the throttle cables are having tight turns when routed correctly. They should exit the right hand switchgear pointing almost straight along the bars, not pointing forward so much. This then points them toward the hole in the speedo bracket. Are they like that?

Exactly that is why I think the manual routes are wrong for the Uk bars as the throttle grip is not above clocks tops but almost level with them. On the US bars they would drop down nicely between the clocks.

On my bike when the throttle cables exit the bars the fixed right angle part of the cable ends means they are pointing not dead horizontaly but very slightly downwards  exiting approximately  3" below the centre line of the switch clamps. The instrument bracket is about an inch and a half below the centre line of the bars but is also angled. The path between the instrument bracket hole and the throttle grip body is not a straight line as the rev counter is in the way.

For the cables to then go upwards they have somehow get past the front of the rev counter as there is no space at the rear of the rev counter due to the brake hose etc. This route is not viable for me - not to mention crossing through the coil gap as well.

You can see there are no tight bends with my present routing plus it should not cause issues when turning left or right as there is just the one gentle swoop/curve of cable.


throttle route 1 by Macabe Thiele, on Flickr

[Nurse Julie]

There is no routing plan in the handbook for UK models Ted. I'll take a photo of my UK K1 routing for you tomorrow.