TOPIC:

When installing my throttle cables on my 77' KZ1000A, I noticed that one of my cables inner cable was frayed at both ends. The ball ends are fine. The outer cable is in very good shape.

Can I replace the inner cable? How difficult are they to repair and installing the ball ends ?

Could purchase new cables but these are shorter ones that work with the lower Super Bike type of handlebars that I have on the bike.

Also, I hooked up the throttle accelerator cable ( the good one ) but not the decelerator or return cable ( the frayed one ). Can I run it this way?

you should get new cables and then shorten them if necessary

measure & order from Barnett, I think Motion pro makes custom lengths also.

If I just order the inner cable instead of replacing the whole cable assembly, how do you attach the barrel ends to the cable?

Have some custom cables made up for you. My BSA experience demonstrated that if you attach your own barrel ends they are not very reliable (of course it could just be that I did a crappy job of it). Ed

Get new cables made. Over time, the cable doesn't stretch, the housing compresses. Lack of regular cable lubing service is usually what causes the wire to fray. WD40 is not a lube, it is a Water Displacement Formula #40. Your cables are open to air which includes water and dirt. New cables are the way to go, and cable lube them often. Just my opinion here.

I carry a spare. You can ride with one. I did for years. I broke one, soldered it and ordered a new one. The repaired one is now my spare.

Does anyone know what the stock length of 77' KZ1000A throttle cables are? The cables I'm using measure 32" in length on the outside cable cover and 36" inside cable length ( barrel end to end ). But the handlebars that are on the bike are a lower Superbike style.

Could inquire at Z1E, which invites questions, is glad to help, and likely gives frequent advise about this.

Click here > www.z1enterprises.com/

For instance, D1 or D2 cables might be just shorter enough to fit nicely.
Or custom cables might be better in some instances.

Good Fortune!

flanderscompany.com/FlanCableSearch.html
Try this place.

I only need a couple Barrel ends. Have to see what's the best way to Solder them on?

According to the Z1 Ent. site, Stock cables for your bike are 43.5" They offer 40" cables for use with lower dragbike style bars. Part # for the shorter cable is MP01-0233. You can replace both cables for less than $20.00. You're going to spend a lot more time and money trying to rebuild the ones you have and you'll still have old cables.

Making your own cable used to be a common practice. I searched for solder on barrel ends a few years ago and couldn't find them. I ended up making molds and pouring my own. I cast the ends right on the cable, so they don't pull off. Soldered ends on throttle cables did OK, but I could never get a soldered end on a clutch cable to hold long term. I only went to this level of effort because I wanted to keep the factory cables with printed Kawasaki part numbers for a 100% original restoration. If that's not a concern, just buy a new cable assembly.