rear brake cable conversion

Wild_Alaskan · 06-10-2012, 11:48 PM

my rear brake pull rod adjusting threads have stripped out so I installed a cable to actuate the rear brake instead. this also keeps the rear brake consistent regardless of what part of the stroke the rear tire is in and prevents the rear brake from dragging in the air when the suspension is all the way relaxed and also when bottomed out. now the changes in geometry are taken care of by the cable housing.

I used a $10 clutch cable off of eBay for some Chinese bike that had the mounting options i wanted and cut the housing and cable to the lengths I needed

SpudRider · 06-11-2012, 01:19 AM

That's ingenious! Nice work, WA!

If you have time, please post closeup photographs of the two mounting points for the cable.

Spud

Wild_Alaskan · 06-11-2012, 01:53 AM

slotted bolt holding the cable against the brake pulling arm.

partially drilled and slotted housing mount

lower housing mount was made from my old motors clutch cable carrier welded the the brake ramrod. this also allows for easy tension adjustability.

i used the old mounting style that the rod used but modified the mounting piece to hold the end of the cable and pinched in the carriers for the mounting piece so it cant fall out if there is a cable going through it.

there is also a protective sheath over the entire cable to minimize damage from rubbing the swing arm

SpudRider · 06-11-2012, 02:25 AM

Thanks for posting the additional photos, WA.

You did an excellent job!

Spud

Weldangrind · 06-11-2012, 10:28 AM

Nice work! I hadn't considered that a poorly designed drum brake could tension the shoes during articulation.

FastDoc · 06-11-2012, 11:44 AM

Excellent work and it answers a question for me too. :idea:

My XR250 used a cable actuated rear drum brake and I never knew why, now I see the advantages. It also is a little nice to not have to adjust the push (pull?) rod when adjusting the chain.

Nice reinforcement work on the swingarm.

That bike is certainly not a pampered garage queen. :wink:

06-10-2012, 11:48 PM	#1
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	rear brake cable conversion my rear brake pull rod adjusting threads have stripped out so I installed a cable to actuate the rear brake instead. this also keeps the rear brake consistent regardless of what part of the stroke the rear tire is in and prevents the rear brake from dragging in the air when the suspension is all the way relaxed and also when bottomed out. now the changes in geometry are taken care of by the cable housing. I used a $10 clutch cable off of eBay for some Chinese bike that had the mounting options i wanted and cut the housing and cable to the lengths I needed __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
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06-11-2012, 01:19 AM	#2
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	That's ingenious! Nice work, WA! If you have time, please post closeup photographs of the two mounting points for the cable. Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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06-11-2012, 01:53 AM	#3
Wild_Alaskan Join Date: Dec 2009 Location: Alaska Posts: 914	slotted bolt holding the cable against the brake pulling arm. partially drilled and slotted housing mount lower housing mount was made from my old motors clutch cable carrier welded the the brake ramrod. this also allows for easy tension adjustability. i used the old mounting style that the rod used but modified the mounting piece to hold the end of the cable and pinched in the carriers for the mounting piece so it cant fall out if there is a cable going through it. there is also a protective sheath over the entire cable to minimize damage from rubbing the swing arm __________________ Dune buggy build http://chinariders.net/modules.php?n...wtopic&t=14470 400cc lifan build vid: http://youtu.be/20HoU8OK_Y0 other fun: http://tinyurl.com/wildalaskan
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06-11-2012, 02:25 AM	#4
SpudRider Join Date: Jul 2008 Location: Idaho Posts: 25,054	Thanks for posting the additional photos, WA. You did an excellent job! Spud __________________ Spud "Never argue with an idiot. He will drag you down to his level, and beat you with experience." Mark Twain 2015 Zongshen ZS250GY-3 (RX3) 2006 Zongshen ZS200GY-2 (Sierra 200) 2005 Honda XR650L 2004 Honda CRF250X 1998 Kawasaki KDX220 Mods made to my Zongshen ZS200GY-2: http://www.chinariders.net/showthread.php?t=6894
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06-11-2012, 10:28 AM	#5
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Nice work! I hadn't considered that a poorly designed drum brake could tension the shoes during articulation. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
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06-11-2012, 11:44 AM	#6
FastDoc Join Date: Mar 2009 Location: Southeastern Washington desert Posts: 14,761	Excellent work and it answers a question for me too. :idea: My XR250 used a cable actuated rear drum brake and I never knew why, now I see the advantages. It also is a little nice to not have to adjust the push (pull?) rod when adjusting the chain. Nice reinforcement work on the swingarm. That bike is certainly not a pampered garage queen. :wink: __________________ Happy to serve.
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