Throttle Cable Pulley??

l008com

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Any old time Mountain Bikers here? In the 90s and early 2000s? Have you heard of a Rollamajig? Ok I'll get back to this in a sec.

Like probably most karts, my throttle cable comes up from the gas pedal, along the rails beside the seat. But then it has this big old loop that goes around so it can feed into the engine from the side. This causes two problems. It tends to kink, which isn't good. And it also tends to catch branches because it hangs out so far. It also catches the back tire sometimes too.

So the rollamajig. Back in the day, mountain bike rear derailers would take the shift cable input from the back. Meaning the cable would come from the handlebars, down the bike, then have to do a big 180° loop to feed into the derailer. This was an absurd setup and mountain bikes don't do it this way any more. But when they still did, a company came out with a device called the rollamajig. It was a pulley that you would essentially put in place of some section of cable housing. It eliminates the tight bend in the housing, and only bends over a actual pulley.

Rollamajig:
img_rollamajig.jpeg


Do these exist in powersports? Seems like a great solution for mechanical brake cables, throttle cables, gear shift cables. Any situation where a cable needs to turn 90° or more. Also when you put these on a bike, it actually noticably reduced the force needed to shift gears. It wasn't just about theoretical friction reduction.
 

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Hellion

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Have you heard of a Rollamajig?

I have not heard of this until now. Thanks for the education.

I typically do not have a problem with kinked cables in my go kart and minibike misadventures because I make sure I have and use enough cable and sheath to prevent kinking. However, I will readily admit that the arc required for smooth operation from the straight run along the frame rails to where it (radically) changes direction to the engine can often make the cable poke outside the boundaries of the kart or bike, making it vulnerable to damage.

So your statement:
it has this big old loop that goes around so it can feed into the engine from the side. This causes two problems. It tends to kink, which isn't good.
...is incorrect in my experience. You need that big old loop but don't make it too big of course. Using the absolute minimum length of cable to connect a throttle that operates perpendicular to the cable run will cause the cable to bind and kink on the corner(s).

What I would suggest to retain the closed environment of the cable and its sheath is to use a throttle cable elbow. They're available in a myriad range of sizes and configurations and you could probably make your own with a tubing bender (and some dies because threads are nice)....

Image 203.jpeg
 

Jimmyjoe

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I have not heard of this until now. Thanks for the education.

I typically do not have a problem with kinked cables in my go kart and minibike misadventures because I make sure I have and use enough cable and sheath to prevent kinking. However, I will readily admit that the arc required for smooth operation from the straight run along the frame rails to where it (radically) changes direction to the engine can often make the cable poke outside the boundaries of the kart or bike, making it vulnerable to damage.

So your statement:

...is incorrect in my experience. You need that big old loop but don't make it too big of course. Using the absolute minimum length of cable to connect a throttle that operates perpendicular to the cable run will cause the cable to bind and kink on the corner(s).

What I would suggest to retain the closed environment of the cable and its sheath is to use a throttle cable elbow. They're available in a myriad range of sizes and configurations and you could probably make your own with a tubing bender (and some dies because threads are nice)....

View attachment 151702
That's cheating. Didn't know they made such a thing.
 

Hellion

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That's cheating. Didn't know they made such a thing.

I know right? Have seen them on myriad vehicles and maybe some machinery(?) but really never said "hey I need one of those"

They are seen on a lot of the newer glut of Chinese cages with wheels ("go karts") where the throttle cable pulls from the rear of the engine and curves under it courtesy of a 90° elbow.
 

65ShelbyClone

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Do these exist in powersports? Seems like a great solution for mechanical brake cables, throttle cables, gear shift cables. Any situation where a cable needs to turn 90° or more. Also when you put these on a bike, it actually noticably reduced the force needed to shift gears. It wasn't just about theoretical friction reduction.

You can find them on some larger Mikuni carburetors like the HSR series.

For the most part, very little in powersports uses cables for anything but a clutch and even clutch actuation is slowly going hydraulic or fully automatic.
 
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