24720-ALE8-E00 CABLE SHIFTER ASSY

[Vivhargreaves]

My friend is losing income due to his rental UXV being down as the internal cable in this assembly snapped.  Does anyone have one or know a fix?

Appreciate any help!

Thanks,

Viv

[CROSSBOLT]

I had to make my own internal cable when mine snapped on the seat release. Should be doable on this. Got a picture? ATV? UXV?

[Vivhargreaves]

It’s UXV,450 Euro4.  I’ll get a photo later of the vehicle and failed part and post.  I can’t help thinking that a fix should be possible but would be great if someone had repaired and could share.  This guy’s losing 90Euro per day as it’s sat idle.

Thanks for the response.

Viv

[CROSSBOLT]

This is part of my cable project:

[Ruffus]

@Viv,
for my understanding:
Is this the seat-opener?
IF yes, I would simply make an external,short cable(line) convenient to reach with a bumble on the end until a ginal repair. This bumble should be reached easily but not accidentily.
https://www.kymcoforum.com/index.php?topic=30847.msg216233#msg216233

[Vivhargreaves]

The cable operates the gear selection and parking brake.  I will upload photos in the next few hours when I get access to the vehicle-thanks

[Vivhargreaves]

Photo showing the snapped cable

[Vivhargreaves]

Photo showing full assembly (missing the other end currently)

[CROSSBOLT]

Photo showing full assembly (missing the other end currently)

Do you have both end portions? The shapes at each end can give a clue as to what to use as a replacement.

[Vivhargreaves]

Karl, I don’t have access to the other end as it it still on the vehicle but the other end is the same as the one shown in the photo.  I’m thinking if the ‘crimping’ can be undone and a similar rigid cable found then a solution is there somewhere.

[Ruffus]

@Vin,
finally got it. Seems to be a 2,5mm cable.
I would look for any motorcycle clutch activating cable, like we had it on older YAMAHAs or older HONDAs, and then adapt ends somehow.

[CROSSBOLT]

Karl, I don’t have access to the other end as it it still on the vehicle but the other end is the same as the one shown in the photo.  I’m thinking if the ‘crimping’ can be undone and a similar rigid cable found then a solution is there somewhere.

I don't see ANY ends! I see a frayed snaggle in that one with the spiral outer housing and can't resolve the picture of the whole cable to see any ends. Ruffus has the right idea by adapting a 2.5 mm clutch cable from a motorcycle. That unravelled end of the outer housing looks a bit gnarly anyway!

[Vivhargreaves]

Here's a photo showing how the cable is attached via a steel crimping to an adjustable end.

We need to find a compatible cable and work out how to open the crimp and replace the cable.  I will measure the cable and report.  If anyone know a bike/ATV that this cable type please shout up.  It has to be a standard cable used for multiple applications where a rigid yet flexible cable is required for a push/pull application.

This guy will lose $7000 by the time a new cable arrived from Kymco!  I have to find a way - it seems doable.

Thanks again to all those taking the time to check out this post and offer your advice!

Have a great day

[Vivhargreaves]

@Ruffus - Thanks I will do that today.  We have access to bike garage/mechanics so we should be able to find a cable!

[Ruffus]

@Viv, pls see pics.
This cable is originally an outboard gear shift item, 6 ft long with on both sides a 5mm thread with counternut. I had to make for my me one side a longer terminal at my YAMAHA  boatmotor.
Easy:
 -take 10mm alu rod
- cut lenght as neccessary
- tap an 5mm thread in one end
- adapt the other end to your needs ( hole, oval, square, etc)
Opening those crimpings do not lead IMO to success, because of lack of a new "press" terminal.