GS 160 Cables ++
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Joined: 11 Jan 2007
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Sun Mar 29, 2020 2:09 pm quote
My GS 160 still has the original shift cable housings and they have seen way better days. The last time I had to replace the inner I found that one of the housings had fully broken, so feeding a new cable through required pulling the tank to line things up. As these cables are original, they are crimped together near the headset and can't be easily replaced one at a time.

The time has come to replace them, and most the rest at the same time.

While I'm in there, the steering bearings are in bad shape so those will get replaced as well.
Measured Cable Lengths:-draft

Cable Housing Length, OD, ID Ferrel OD, ID Inner Length, Diameter Notes
Shift 160cm, 5mm, 2mm 6.0mm, ?.?mm 2m, 1mm
Clutch 170cm 46 ? 6.0mm ?.?mm
Throttle ????cm 7mm 5mm 8mm ?.?mm
Choke 47cm 5mm 2mm 6.0mm 0.8mm
Rear Brake 76.5cm 7mm 5mm 8.0mm 2.5mm



Last edited by oopsclunkthud on Sat Jun 13, 2020 4:36 pm; edited 3 times in total
bodgemaster
1963 GL, 1976 Super (x 2), 1974 Primavera (x 2), 2006 Fly 150
Joined: 26 Sep 2013
Posts: 5299
Location: So Cal
Sun Mar 29, 2020 2:27 pm quote
So long crimped cables, it was good knowing ya. I’d say you got your money’s worth. Gonna to try and get a few more years out of these.

8590CB39-4025-45FE-8076-0C1474240B49.jpeg



Last edited by SoCalGuy on Sun Mar 29, 2020 2:29 pm; edited 1 time in total
Moderator
P200 PX150
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Location: Hustletown, TX
Sun Mar 29, 2020 2:28 pm quote
Patrick that thing is absolutely gorgeous.
Good luck on the swap.
Ossessionato
1964 GS 160 MK II, 1967 Vespa GT, 1968 SS180, 1964 Vespa GL, 1964 Vespa VBB, 2006 Buddy 125, 2013 BMW C650GT
Joined: 07 Apr 2008
Posts: 2991
Location: Boca Raton, Florida
Tue Mar 31, 2020 8:26 am quote
Thanks a lot Patrick. I'm getting ready to put my rebuilt motor back into mine...with original outers. Now I know what I have to look forward to!

Good luck and let us (me) know how it goes!
Banned
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Joined: 11 Jan 2007
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Location: San Francisco
Tue Mar 31, 2020 9:34 am quote
I don't trust most the pre-made cables for quality or length so have decided to measure the existing and make my own. I got bulk cable housing from SIP in both gray waffle, and black.

I used the old housing to pull the new bulk length through and then measured the old.

Shift Cable: 160cm, clamped together ~10cm from headset end

IMG_4997.JPG
old cable length. clamp position 10cm from end

IMG_4994.JPG
pulled enough cable through to mark the length and then pulled it back through before cutting.

IMG_4999.JPG
trimmed, ends fitted, and used shrink wrap to join the cables where the clamp had been.

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Sat Apr 18, 2020 8:39 pm quote
After working on the lower bearing for a few hours off an on with a slide hammer I decided it was just not delivering enough impulse. Ground a long extension to catch the lip, and it moved on the first tap.

Then moved on to the guides for installing the new one

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7EE19F71-0022-4E2C-8B52-7F44645DDA53.jpeg

Ossessionato
1964 GS 160 MK II, 1967 Vespa GT, 1968 SS180, 1964 Vespa GL, 1964 Vespa VBB, 2006 Buddy 125, 2013 BMW C650GT
Joined: 07 Apr 2008
Posts: 2991
Location: Boca Raton, Florida
Sat May 02, 2020 6:15 am quote
Thanks for the info, especially the lengths.

Did you need to cut the clamp (how?) or will they pull through together?

I got to the same point where premade outer lengths were annoying. I usually use what I call a middle outer when installing.

I run string trimmer line through the middle and original outer, pinch bolt, pull the original out the middle in, make one the same length as the original, string the trimmer line through it and pull the middle one through and the correct length new one is in the right place.

Thanks again, good to see you!
Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1423
Location: Siam
Sat May 02, 2020 10:15 pm quote
Which opening, left or right, will the new clutch cable come out of? I ask because I believe it normally comes out the left side opening, but some people believe it has a smoother path coming from the right side opening.
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Mon May 18, 2020 1:15 pm quote
nomadinsiam wrote:
Which opening, left or right, will the new clutch cable come out of? I ask because I believe it normally comes out the left side opening, but some people believe it has a smoother path coming from the right side opening.
On the GS there is only one opening, I'll photograph it when I get the clutch cable in there.

project is slow going, I had to pull the exhaust to get access to the rubber grommet that the cables pass through. while I had the exhaust off I took a look up the intake to the piston, looked good. rotate the crank and see an odd line on the top ring, reach in with a probe and well...

60721070514__027335F0-C412-4864-9568-6C20CC3F2E83.JPG

IMG_5172.JPG

Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1423
Location: Siam
Mon May 18, 2020 8:41 pm quote
I've noticed a few things on my GS160. First was trying to find a long enough rear brake cable housing. I ordered two (one eBay and one from a distributor) and both were too short. I finally found a source who cut it longer from a roll which I cut to length.

Do you have the copper ring that goes up into the the exhaust port? The exhaust stub tightens down onto this copper ring. It took ages for me to find one, but finally found one from Scooterwest. They still now have them in stock as I just received another one for the SS I'm building. No other distributors that I tried had it.
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Fri May 22, 2020 3:14 pm quote
Since I have the fork out, cleaning up the steering lock.

8518A6A4-D3FB-4DC7-AA83-18B2CC5734DA.jpeg

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Mon May 25, 2020 3:39 pm quote
Lock back in place with new rubber

IMG_5204.JPG

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Mon May 25, 2020 3:48 pm quote
replaced the clutch cable: existing cable 170cm, not 100% sure it was original but length was never an issue so keeping it the same.

fullsizeoutput_257a.jpeg

Banned
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Mon May 25, 2020 3:58 pm quote
Went to replace the rear brake cable and the stupid "SIP super premium extra fancy-pants" cable is 4cm shorter than stock.

Guessing no one in Germany actually runs a stock GS engine.

so the correct cable sleeve is 7mm OD and length of 765mm. ferrule at one end 8mm OD.
cable inner is 2.5mm

now ordering bulk cable...

IMG_5209.JPG

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Mon May 25, 2020 7:57 pm quote
Cut the rear brake cable, made a 40mm spacer.

FB92D704-AF16-4999-9AE7-9D16DE2DEAED.jpeg

Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1423
Location: Siam
Tue May 26, 2020 12:11 am quote
oopsclunkthud wrote:
Went to replace the rear brake cable and the stupid "SIP super premium extra fancy-pants" cable is 4cm shorter than stock.

Guessing no one in Germany actually runs a stock GS engine.

so the correct cable sleeve is 7mm OD and length of 765mm. ferrule at one end 8mm OD.
cable inner is 2.5mm

now ordering bulk cable...
Been there, done that. It happened with a rear brake cable housing and a wiring harness. It gets pretty old after awhile.
Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1423
Location: Siam
Tue May 26, 2020 2:02 am quote
This is all interesting. I had never bothered to measure my housing lengths which I certainly should have. I would have prevented ordering headaches. As you can see from the chart below, the cable lengths for large frame 10" models are not the same as the lengths you are showing. I had the same problem finding a rear brake housing long enough. I had ordered a pre-cut cable and housing specifically for a GS160 and it was clearly too short as you experienced. Buying housing in bulk lengths and cutting to fit seems to be the answer for these bikes (GS and SS) and maybe a few others as well.

Vespa Cable Lenghts.jpeg

Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1423
Location: Siam
Tue May 26, 2020 5:49 am quote
Now, I feel like I'm beating a dead horse, but anyway.
This is a rear brake cable I ordered some time ago. It is listed specifically for a GS160 or SS180. The label says it will fit practically everything. Isn't that wonderful? After trying to install it, I found that it is far too short for a GS160. In that list above, it says 71cm. They didn't even get close to that as it measures 69.5cm. As Mr Oopsclunkthud has pointed out 76.5 works, so I will say 76cm is the minimum needed. Keep in mind that this is not some schmo part from a dicey ebay vendor; this is the offering from a top end company.

MP1.jpeg



Last edited by nomadinsiam on Tue May 26, 2020 5:53 am; edited 3 times in total
Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1423
Location: Siam
Tue May 26, 2020 5:50 am quote
The short end of the stick for me. Maybe a separate thread for everyone to post information about genetically defective parts needs to be started, or maybe not. I need to start visiting hardware stores and home improvement centers more often to see if I can improvise a bit more.

MP2.jpeg

Banned
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Tue May 26, 2020 7:28 am quote
thanks for posting the chart, even if not all the data is accurate. It's a useful reference. the GS/SS engine is probably most of the difference in the way the cables route.

Think I'll add a summary chart to the start of this thread and maybe start a wiki page.

One good thing I'll say for SIP is that they do list the measurements, so you know what you are getting. It's just that without knowing what length it should be you can't trust them to have the correct bikes listed for a part.

Oh, and the ferrels SIP sells are really nice, and again they list the dimensions.
Molto Verboso
Vespas 1964 GS160, 1965 SS180, 1977 V9A1T, 1983 PX150E
Joined: 16 Apr 2011
Posts: 1423
Location: Siam
Tue May 26, 2020 8:10 am quote
oopsclunkthud wrote:
thanks for posting the chart, even if not all the data is accurate. It's a useful reference. the GS/SS engine is probably most of the difference in the way the cables route.

Think I'll add a summary chart to the start of this thread and maybe start a wiki page.

One good thing I'll say for SIP is that they do list the measurements, so you know what you are getting. It's just that without knowing what length it should be you can't trust them to have the correct bikes listed for a part.

Oh, and the ferrels SIP sells are really nice, and again they list the dimensions.
That chart was first posted by another member on this forum. I can't remember who.

I agree about SIP. Their website has more useful information than any other vendor site. Sometimes I look at it just to see the dimensions of parts without any need to order anything. It looks like they have spent very long hours creating the content for it.

This is the hardest thing about ordering:

"It's just that without knowing what length it should be you can't trust them to have the correct bikes listed for a part."

If someone is missing a part and needs it, they have no idea what it should look like. I had someone say to me once, "Just order the same stator coils it has on it now." I then say, "Well, it has some shitty Indian made 12 volt coils that that I'd like to replace with the correct 6 volt coils that it came with before it was modified. It has no battery." I then get no answer. It can't be that hard, can it, to get things right?
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