Note: This method will work for throttle, clutch, and gear cables. If the gear cable sheaths have never been replaced, then you will need to replace both sheaths at the same time. This is because the 2 gear cable are fastened together at the factory. You won’t be able to pull one gear sheath out without pulling the other along also.
1. Go to your local hardware store and buy 14 feet of braided cable about the same diameter as a typical inner control cable.
2. Place a pinch bolt at one end of the braided cable.
3. Remove the new inner cable from the new sheath.
4. Run the braided cable into the sheath and butt the sheath up to the pinch bolt.
5. Remove the old inner cable from the old sheath.
6. Run the braided cable into the old sheath from the top (headset end).
7. Place a pinch bolt at the other end of the braided cable.
8. Now you should have the braided cable going through the old and new sheath with a pinch bolt at either end. See the diagram below.
9. Place a piece of tape over the two ends of the sheaths that meet in the middle. This will prevent the sheaths from getting stuck on anything in the frame.
10. Begin to pull on the cable from the engine end while you are pushing the cable down into the headset. Don’t pull too hard, you do not want to damage the new cable sheath. If the cable gets hung up, back it out some and pull some more.
11. After you pull the old sheath entirely out,the new sheath should now be in place.
12. Undo the pinch bolts, remove the long braided cable, grease the new inner control cable and feed it into the new sheath. Hook it up and you are ready to go. Note:You may have to trim the new sheath some to match the length of the old sheath.
Cable housing install