• THE CONTACT
  • THE BLOG
  • THE BIKES
  • THE ABOUT
  • THE PROCESS
Menu

DAVMOMOTO

CUSTOM METAL
  • THE CONTACT
  • THE BLOG
  • THE BIKES
  • THE ABOUT
  • THE PROCESS
An internal cable throttle that was made for the 1957 Triumph Freebird project. The controls that were on the bike were pretty basic stock units, and a pair of reverse brake and clutch levers were chosen to replace them. With the internal cables on …

An internal cable throttle that was made for the 1957 Triumph Freebird project. The controls that were on the bike were pretty basic stock units, and a pair of reverse brake and clutch levers were chosen to replace them. With the internal cables on the levers, it will make for a clean set of bars to tuck the throttle cable inside the bar and lose the external throttle case. The bars are a 1” set of Norman Hyde mustache type that I had cut the end off to fit a 7/8” throttle a couple years back. Interestingly enough, the cut-off end was found and grafted back on to do this job.

Making an internal cable throttle for the 1957 Triumph Freebird bike.

February 2, 2019
These are the brass reverse levers going on the bike. They are made by hand in Ukraine and are a BMW knock-off. The holes for the screws had to be enlarged to allow the cams to slide enough to tighten them up and the cable perches needed filing out,…

These are the brass reverse levers going on the bike. They are made by hand in Ukraine and are a BMW knock-off. The holes for the screws had to be enlarged to allow the cams to slide enough to tighten them up and the cable perches needed filing out, but hey are otherwise strong serviceable units. This particular pair was chosen because the cable exits toward the back wall of the inner handlebar, allowing room for the throttle mechanism.

The Honda components that make up the internal throttle cable mechanism. Made for a 1969 Z50 minibike, they were chosen because they leave the interior of the handlebars clear enough to get the brake cable through. The longer piece at the top of the…

The Honda components that make up the internal throttle cable mechanism. Made for a 1969 Z50 minibike, they were chosen because they leave the interior of the handlebars clear enough to get the brake cable through. The longer piece at the top of the pic is the slide that pulls the cable end, and the other piece is the cable sheath holder. The cable sheath has a threaded end that screws into the holder, making for a solid joint that can’t back out like most cable holders.

The hardest part to make was the internal spiral that drives the slide.. getting the angle of the slide was not hard, but getting the spiral to lay down perfectly flat and getting the right tolerance between the bar was tricky. Although the throttle…

The hardest part to make was the internal spiral that drives the slide.. getting the angle of the slide was not hard, but getting the spiral to lay down perfectly flat and getting the right tolerance between the bar was tricky. Although the throttle is based on the Honda design, it was changed a little by adding the ring at the bottom to act as the flange that rides against the bar. A thinner outer tube will cover the spiral.

The inner workings of the throttle mechanism can be seen in place. The cable holder is held in place a couple of different ways. There is a round keyed portion at the top of the slot that keeps the top located correctly, then a flange that slides ov…

The inner workings of the throttle mechanism can be seen in place. The cable holder is held in place a couple of different ways. There is a round keyed portion at the top of the slot that keeps the top located correctly, then a flange that slides over the bar and keeps it from being able to come out the top, and finally a screw that secures it from the bottom. The slot for the slide was cut by hand and made a few millimeters longer than the stock Honda one to accommodate the longer travel of the Amal carb slide.

This is the flange that slides over the cable holder. It also is the spacer the outer throttle tube rests on, and the ring at the end keeps it from sliding inward on the bars. A stopper screw was turned from a hex bolt. In addition to anchoring the …

This is the flange that slides over the cable holder. It also is the spacer the outer throttle tube rests on, and the ring at the end keeps it from sliding inward on the bars. A stopper screw was turned from a hex bolt. In addition to anchoring the bottom of the cable holder, it keeps the throttle tube from being able to slide off the end, and limits the range of the throttle twist. The exit hole for the cables can be seen on the underside of the bars. A shroud (seen below) was made to go around the hole to support the cable and keep it from resting on the edge of the hole.

Other than the cable for the brake, this is all that will be on the right side.

Other than the cable for the brake, this is all that will be on the right side.

That is about as clean as it gets on the handlebars.

That is about as clean as it gets on the handlebars.

The exits for the cables were given some shrouds that were brass-brazed on.

The exits for the cables were given some shrouds that were brass-brazed on.

Because there are two cables exiting the handlebars on the right side and they are not as fat as the left-side clutch cable, a thinner, taller shroud was made.

Because there are two cables exiting the handlebars on the right side and they are not as fat as the left-side clutch cable, a thinner, taller shroud was made.

Tags #bf11invitedbuilder, #bf11, #bornfree11, #freebirdbike
← Making a seat mount and gas tank mods for the 1993 Harley Davidson FXR custom1993 FXR Softail custom and 1978 CB750 updates. →

WTF is going on here?

Featured
Jul 21, 2025
1980 Honda Z50R Chrome Custom Electrical Upgrade.
Jul 21, 2025
Jul 21, 2025
Jul 9, 2025
1962 Honda CB77/CL72 Race Bike Completion.
Jul 9, 2025
Jul 9, 2025
Jul 1, 2025
The 1980 Honda Z50R Chrome Custom completion.
Jul 1, 2025
Jul 1, 2025
Jun 23, 2025
The 1980 Honda Z50R Chrome custom build update.
Jun 23, 2025
Jun 23, 2025
Jun 21, 2025
A Tribute to the Z50RD. 1980 Honda Z50R Chrome Custom.
Jun 21, 2025
Jun 21, 2025
Apr 13, 2025
1979 Honda Z50R Restoration.
Apr 13, 2025
Apr 13, 2025
Dec 1, 2024
Finishing the 1967 Triumph Mountain Cub Restoration
Dec 1, 2024
Dec 1, 2024
Oct 10, 2024
Another 1967 Triumph Mountain Cub in the shop
Oct 10, 2024
Oct 10, 2024
Sep 25, 2024
Back from the Denton Texas Burnouts Custom Motorcycle Show.
Sep 25, 2024
Sep 25, 2024
Aug 28, 2024
1963 Ducati Diana 250 Mark III completion
Aug 28, 2024
Aug 28, 2024

 

XXXXXXXXX