Gear/ throttle Cable Replacement
This section shows a quick step by step of replacing cables on an older type (pre P-series) scooter. The first step is to remove the headlight unit with two small screws located at about 4 and 8 o'clock when looking at the headlight. The unit can then be hinged out from the bottom and lifted to release a top pin from the headset. The bulb holder can be disconnected by undoing the two metal clasps that attach it to the headlight.
Remove the speedometer by undoing the center of three bolts when looking at the bottom of the headset. The speedo drive and speedo bulb will also have to be disconnected as you pull the speedometer clear. Once this is done you should see something similar to the picture below.
This sections shows how to replace the inner and outer cables for the gear selector box/ throttle slide assuming that the cables are ready for the trash.
(1) Disconnect the engine end of the cable from the gear selector box/ throttle slide and loosen the headset end out of the rotating ends of the throttle tubes. Make sure you hold on to the little metal cap which locates in the cable end block. You'll need these when you thread the inner cable.
(2) Pull the cable inner out of the outer with a pair of pliers. Once it is out you can clip the head of the outer cable to get rid of the crimped metal end as this could get caught as you pull it through the frame.
(3) Clean the end of the old cable outer and wrap in a spiral motion with a piece of electrical tape. This type of tape works well because you can stretch it to make it really tight. Take the new cable outer and place it face to face with the old and continue the wrap around it for about 3 inches. Repeat the process in the other direction (from the new to the old). Once this is secure it should look like the picture below.
(4) At this point a helper is really handy. One person holds the cable at the headset straight up in the air. At the other end you pull the cable slowly through the frame as person nuber 2 feeds it in. It should slide right through and poke out the proper hole near the engine like below.
(5) Carefully unwrap the tape from the cables, lubricate the outer, and thread the inner cable. Make sure that if you had the type of scoot that has a small metal end cap that fits over the cable end, you thread this on the cable before the inner. The last part is to reconnect all the cables as you found them and make sure they are adjusted correctly with the small adjuster screws at each cable end.