This subject is probably now yesterdays news but we had a lot of problems
with kinked cables before I found out the problem. Unfortunately if the
outer sleeves are not routed right, the cable in the throttle box kinks and
thats the end of it (ie: the cable has to be replaced). This is in my
opinion a major weakness of this particular design.The first 6 inches of the
cables should be rigid and not flexible as in the current setup.
We found the supplied cable sleeves (including the replacements) to be too
long for our installation. This simply results in an unacceptable number of
bends and the inevitable jamming and kinking of the inner cable.
Our best solution was to cut through the cable sleeves about 1 inch from the
carburettor ends and to cut out a portion of the outer sleeving. The
remaining ends are then joined back together by gluing them inside a short
alumiinum tubing sleeve (as found in model shops - brass would be ok too).
An added advantage is that without the screw ends to get in the way, the
cable outers can easily be passed from the tunnell end through the narrow
gap between the undercarriage frame and the top of the tunnel. We found this
nearly impossible with the screw ends attached (NB they cannot be removed at
the cable ends).
It is essential that the cables are routed in a very lazy S shape with no
tight bends whatsoever (ie: straight out from throttle box, bending gently
outwards & upwards, passing through top of tunnel then back inwards past the
carb filters to the carb attachment points). We used some strategically
shaped tiewraps at the engine compartment ends to keep the cable paths
exactly as we wanted them. Ours have to route outboard of the rotax filters
but this will be different if a plenum box is fitted.
Having replaced two cables even before our first flight had always been a
worry and we always look and check inside the throttle box as part of our
pre start up checks to make sure there is no sign of kinking.
However after 6 months flying and no problems to date we are confident we
have got things right. Of course the occasional squirt of light oil helps
too.
Hopefully this hasnt confused too much.
Carl & Dot
----- Original Message -----
From: "Terry Seaver" <terrys@cisco.com>
Subject: Re: Europa-List: Throttle Cables
>
> Hi Paul,
>
> Do cut the cables back to an appropriate length, re-using the fitting in
the outers at the carb
> end. Cut the ends of the inner (carb end) with a dremel wheel after first
soldering at the place
> to be cut, to prevent frayed ends.
> We had the throttle cables get very 'sticky' just before first flight. No
amount of lube would
> make it better. We took the outer part of the cable to the local bike shop
and got a replacement
> outer, which lasted about 150 hours. We then got another outer, teflon
lined this time, which
> will hopefully last longer.
>
> regards,
> Terry Seaver
>
> Paul McAllister wrote:
>
<paul.mcallister@qia.net>
> >
> > Hi All,
> >
> > I am installing my throttle cables and they seem very long. Where does
all of the excess go?
> >
> > Paul
> >
>
>
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