Himalayan new handlebar too high! Cl/br/th cables too short!

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Hello friends!

I just bought a ProTaper Evo Adventure High handlebar because it's thicker (28mm vs. original 22mm) and the riding position is better (see attached photo 1).

However after installing it I realized that these 3 cables are too short for my new handlebar:

(1) Clutch cable (left)
(2) Brake cable (right)
(3) Throttle cable (right)

Do you know where can I get longer alternatives?

I've read somewhere that the clutch cable for the Bullet 350 is 2" longer and fits well, but no idea about the other two.

***

Furthermore during this process I've had to disassemble the plastic box where the throttle cable is located (with the on/off & start buttons), and now I have this C-shaped standalone plastic piece (see attached photo 2) which I can't figure out where to put. Does anyone knows how to put it back?

Thanks a lot!!!

[stinkwheel]

Welcome to the wonderful world of customisation. Change one thing, have to alter all the other things it's attached to.

You're probably looking at having custom cables made I'm afraid. (or learning to make your own).

Also the brake is hydraulic so it's a hose, not a cable which will need new fluid bleeding through after you get a longer one made.

One of the cheapest places I've seen for custom cables is carrot cycles. They also make custom brake hoses. You'll either need to very accurately measure them and describe the fitments or (better) send them the existing ones with a note as to how much longer you want the new ones made. Best bet is to give them a ring up and ask.

https://www.carrotcycles.co.uk/

Your plastic bit looks like it is probably the cable clamp. Does it slot into the upper half of the switchgear and hold the electrical cables in position against the housing when the screws are pushed through and tightened?
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

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Hi,

Thanks a lot for your reply!

I forgot to mention that I am located somewhere in South America, in the midst of a round-the-Americas tour (been traveling for a year now), heading to Patagonia soon.

So buying the hydraulic brake cable from that shop won't be possible for me as I need an urgent solution.

Are you certain there are NO other cables in the market, from Royal Enfield or some other manufacturer, which work with the Himalayan?

Wouldn't Bullet 350's hydraulic brake pipe (which I called "cable") also work on the Himalayan and be 2" longer, considering that its clutch cable works too and is also 2" longer?

Same for the throttle cable.

***

About the plastic part, I don't quite understand how it works because the distance between the screw holes is slightly larger than the distance between the screw holes on both halves of the switchgear box.

Do you know where can I find a photo or the drawing for this part or something?

Thanks in advance for your help!

[wr6133]

[Easy-X]

Curious as to why you'd fit new handlebars mid-tour? And 28mm?! 25mm surely? What are you, a giant?
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[stinkwheel]

I'd say if a bit from a bullet fits a Himalayan, it was pure luck.

Single calliper motorcycle brake hoses are reasonably universal. You need the hose with a banjo on either end, the rest's down to length. The one on my Bullet wasn't designed for it but I'd expect a bullet one would be a lot shorter than a Himalayan one given the relative amount of suspension travel on the two bikes.

Cables can be a bit more fussy because they have to have the correct size nipple on either end, the correct adjuster AND the same amount of free movement.

Am I certain no other cables would fit? No. I'm certain a cable off SOMETHING would fit. Finding what it is would probably only be possible if you find someone else who has already done this.

There must be someone in Patagonia who makes Bowden cables. They aren't all that tricky to make. An agricultural suppliers would probably be the best bet.

Or just move the controls nearewr the middle of the bar.

Or if it's a real deal-breaker and you absolutely HAVE to fit those bars, bastardise the cable routing. If you don't take them neatly along the bar then through the headlamp/under the tank, you'll get a lot more reach. I've run bikes with the clutch and/or throttle cables going over the outside of the tank before today. Untidy but functional. Same goes for the brake hose. Just be aware you could catch them on passing branches.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

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Hey guys,

Thanks a lot for your replies

About the plastic part I figured it out, it goes on the left side handlebar box where the choke is, instead of the right side one, that was a bit silly on my part. I disassembled everything and had a hard time putting things back together.

***

About the rest, I managed to make a custom brake fluid hose at some workshop where they only do custom hoses.

About the throttle cable, I couldn't find any so I'll just pass it beneath the tank instead of in front of it, so I gain that extra inch I was missing.

And about the clutch, I bought a longer cable, and now when I turn the bike to the left, it no longer tightens it, so it's good. However now that the cable is longer, the wire inside is always loose, and I can never make it tight. I've seen there are two nuts but I think this is just to tighten the cable, but not the inner wire, isn't it?

Is there a way to tighten the inner wire? It doesn't seem so by looking at the mechanism, unless I can move the lever where the clutch cable connects to the engine, to the left side, to gain an extra inch; is it possible to move that lever?

I'm waiting for this to head south before the winter hits the Patagonia, hope to make it on time!

Cheers

[yen_powell]

You adjust the inner wire by lengthening or shortening the outer casing, hence the nuts on the cable.
____________________
Blackmail is a nasty word........but not as nasty as phlegm!
XT1200Z and a DR350 in bits

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OK Thanks I'll try it tmr.

About throttle cable I still have the original one only... any clues on a throttle cable from a famous brand that could work?

Right now I'm in Santiago, Chile, and around here I haven't found any shop where they sell standalone throttle cables.

So I think I'd better look for a throttle cable from some a model from some famous brand like Honda or Suzuki, that'd be easier to get from the official parts store.

If anyone has a clue on a throttle from some model from some other brand that would do the job, or how to manually adapt the stock one, it'd be great to hear

[stinkwheel]

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Worth noting that bicycle cables usually come in roughly two grades: thin stuff for brakes and thicker stuff for gears. The latter being the closest to throttle cable material.
____________________
Royal Enfield Continental GT 535, Husqvarna Vitpilen 401, Yamaha XSR700, Honda Rebel, Yamaha DT175, Suzuki SV650 (loan) Fazer 600, Keeway Superlight 125, 50cc turd scooter

[stinkwheel]

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