What cables are most conversions using?

AMA714 · Post by **AMA714** » April 30th, 2011, 8:21 am

I have built my 08 CRF250-CR500 conversion using the stock 500 clutch and throttle cables. Is there a certain year CR250 that has cables with a little longer length??
These will work, but a couple extra inches would be better.

Gravel Scratcher · Post by **Gravel Scratcher** » May 1st, 2011, 3:13 am

AMA714 wrote: but a couple extra inches would be better.

don't we all wish for that

http://www.youtube.com/user/500bigbore · Post by **Roostius_Maximus** » May 1st, 2011, 6:58 am

2202 250 cables, longer but the same ends

AMA714 · Post by **AMA714** » May 1st, 2011, 12:07 pm

Thanks Roost

Post by **AlisoBob** » May 1st, 2011, 3:28 pm

Roostius_Maximus wrote:2202

Arent we all supposed to be flying are own spaceships and teleporting by then?

Shit, maybe Clyde will have actualy competed in his first hillclimb by then....

AMA714 · Post by **AMA714** » May 9th, 2011, 11:10 am

I guess that I can run the 500 cables until I really need to buy new ones, I wonder how much longer the 02 stuff is.

Also, I took a look at the brake lever... I would have to bend it out 8-10mm to get it to clear the clutch cover!!!! That seems like a lot. Is there a better brake lever to use? Like a CR250

mxdogger · Post by **mxdogger** » May 9th, 2011, 7:24 pm

AMA714 wrote:I guess that I can run the 500 cables until I really need to buy new ones, I wonder how much longer the 02 stuff is.

Also, I took a look at the brake lever... I would have to bend it out 8-10mm to get it to clear the clutch cover!!!! That seems like a lot. Is there a better brake lever to use? Like a CR250

Zach you can use a cr250 brake pedal from a 1997-1999, it will clear the clutch cover like it was ment to.

zorak-2 · Post by **zorak-2** » May 9th, 2011, 10:41 pm

just bend it and you will be ok. thats what i did on my 05 build and have no issues with it.

kball1313 · Post by **kball1313** » May 10th, 2011, 9:35 pm

This is from a search I did on a similar topic on a KTM site. It's good so you know how the cables compare year to year. Doesn't have all the answers, but gives a bit of help. My 01 cr250 has a steering damper, flexx bars, 2 inch risers. I used the 2000 250 cable run to my pwk and it works great.

Throttle cables:
1993-96 CR250R cable = 2.8" longer than stock KTM...17910-MAC-670
1997-99 CR250R cable = 4.3" longer than stock KTM...17910-KZ3-B00
2000 CR250R cable = 4.9" longer than stock KTM........17910-KZ3-J20

cryzsurfer · Post by **cryzsurfer** » May 11th, 2011, 4:30 am

To make my stock cable work with my ASV lever I heated the end up a bit to get the little metal goodie that covers the end of the cable sleeve to come loose and pulled it up and out of the way. I then got a vaer sharp pair of electrical snips and cut about ~ .300" off the length of the cable sleeve and squared it up nicely. I refit the sleeve protector back over the fresh cut area and it did the trick. You can cut as much as needed to get the right adjustment.
Craigus

AMA714 · Post by **AMA714** » May 11th, 2011, 6:58 am

Just bought a 99 brake lever, with master, remote fluid res, clevis all for $10
I love Flea-bay

cr_denny · Post by **cr_denny** » May 11th, 2011, 2:58 pm

For what it's worth, I spent a number of hours running around different shops to find throttle and clutch cables with the correct ends on them to give me a few more inches, with not much luck.

Check out Motion Pro's website and you can order custom ones. I didn't think the price was too bad ($35 each) considering all of the dead ends I came across trying to get a dealer to let me browse their stock for a match. I'm very happy with the quality and it fit my build better as I had some routing issues with my larger capacity aluminum tank. Nice guys to deal with and they got them to me in about 7-10 days.

AMA714 · Post by **AMA714** » May 12th, 2011, 7:07 pm

mxdogger wrote:
AMA714 wrote:I guess that I can run the 500 cables until I really need to buy new ones, I wonder how much longer the 02 stuff is.

Also, I took a look at the brake lever... I would have to bend it out 8-10mm to get it to clear the clutch cover!!!! That seems like a lot. Is there a better brake lever to use? Like a CR250
Zach you can use a cr250 brake pedal from a 1997-1999, it will clear the clutch cover like it was ment to.

Dogger... the 99 brake lever will clear, but the 08 CRF bolt is too short in the shoulder and the 99 CR bolt threaded end is way to small... Back to the drawing board...

blownbillybob · Post by **blownbillybob** » May 13th, 2011, 7:44 am

Find the wright size Allen bolt to fit the threads in the frame and length, chuck the Shoulder bolt in a lathe and drill it out to fit the Allen bolt!!!

UknowDamright · Post by **UknowDamright** » May 13th, 2011, 8:25 am

AMA714 wrote: I wonder how much longer the 02 stuff is.

I used a 2003 CR250 throttle cable for my conversion and it's only a couple inches or so longer than the stock CR500 cable.

AMA714 · Post by **AMA714** » May 17th, 2011, 9:33 am

blownbillybob wrote:Find the wright size Allen bolt to fit the threads in the frame and length, chuck the Shoulder bolt in a lathe and drill it out to fit the Allen bolt!!!

Can I borrow your lathe...lol

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