Replace Remote Suspension Lockout Cable: A Step-by-Step Guide

Hey everyone! So, you've got a frayed cable on your remote suspension lockout and you're looking to replace it? Awesome! You've come to the right place. Replacing a cable might seem daunting at first, but trust me, with the right guidance, you can totally nail this. In this comprehensive guide, we'll dive deep into everything you need to know about cable replacement for your remote suspension lockout. We'll cover identifying the right cable, understanding different cable head types, the tools you'll need, a step-by-step replacement process, troubleshooting common issues, and even some maintenance tips to keep your new cable in tip-top shape. Let's get started!

Understanding Remote Suspension Lockout Cables

Okay, let's break it down. Remote suspension lockout cables are a crucial part of your bike's suspension system, allowing you to control your fork or rear shock's travel with a simple flick of a switch on your handlebars. This is especially handy for climbing or riding on smooth surfaces where you want maximum pedaling efficiency. Think of it like this: when you lock out your suspension, you're essentially turning your mountain bike into a rigid bike, preventing energy loss from suspension bob. Understanding the cable is the first step in identifying the right replacement. A frayed or damaged cable can lead to inconsistent lockout performance or even complete failure, which is why it's important to address this issue promptly. These cables are typically made of stainless steel or galvanized steel strands, providing strength and flexibility. The outer housing protects the inner cable from dirt, debris, and damage. It's essential to use high-quality cables to ensure smooth operation and longevity. Before we get into the nitty-gritty of replacement, let's talk about the different types of cables you might encounter.

Types of Cables and Cable Heads

Now, when it comes to cables, not all are created equal. There are different types of cables and, more importantly, different types of cable heads. This is where things can get a little tricky, but don't worry, we'll navigate through it together. The cable head is the little metal piece at the end of the cable that anchors it to the lockout mechanism. Knowing the cable head type is crucial because using the wrong one can prevent the system from working correctly. The user mentioned a 3mm cable head, which is a common size, but there can be slight variations in shape and design. Some cable heads are barrel-shaped, others are cylindrical, and some even have a specific mushroom shape. These variations ensure a secure fit within the lever and actuator mechanisms. The cable itself also comes in different diameters, typically ranging from 1.1mm to 1.5mm for mountain bike suspension systems. Using the correct diameter is essential for compatibility with your specific lockout system. The key is to carefully examine your old cable and its head before ordering a replacement. Take detailed pictures or even bring the old cable to your local bike shop for comparison. This will save you a lot of headaches down the road. Understanding the nuances of cable and cable head types is the first step in ensuring a successful replacement.

Identifying the Correct Replacement Cable

So, you've got your old cable out, and now you need a replacement. But how do you make sure you're getting the right one? This is where accurate identification becomes super important. The first thing you'll want to do is measure the length of the old cable. Make sure you measure both the inner cable and the outer housing. A cable that's too short won't reach, and one that's too long will create slack and potentially interfere with other parts of your bike. Next, pay close attention to the cable head. As we discussed earlier, the shape and size of the cable head are critical. Compare it to online images or consult your bike's manual (if you have it) to determine the exact type. The user mentioned a 3mm cable head, but it's always good to double-check. You can use a caliper to get precise measurements. If you're unsure, taking the old cable to a local bike shop is a great idea. They can help you identify the cable and even recommend a suitable replacement. When looking for a replacement, consider the quality of the cable. Stainless steel cables are a good choice because they resist corrosion and provide smooth operation. The housing should also be durable and flexible enough to route properly through your bike's frame. Don't skimp on quality here; a good cable will last longer and perform better. Once you have the correct replacement cable, you're ready to move on to the next step: gathering your tools.

Tools Needed for Cable Replacement

Alright, before we dive into the actual replacement process, let's make sure you've got all the necessary tools. Having the right tools makes the job much smoother and prevents potential damage to your bike. Here’s a list of essential tools you'll likely need:

• Cable Cutters: These are specifically designed to cut cables cleanly without fraying them. Regular wire cutters can crush the cable and make it difficult to thread through the housing.
• Allen Keys (Hex Wrenches): You'll need these to loosen and tighten bolts that secure the cable and housing. A set of various sizes is ideal.
• Pliers: Pliers can be helpful for gripping and maneuvering the cable and housing, as well as removing any stubborn parts.
• Cable Housing Cutters: If your cable housing needs to be shortened or replaced, these cutters will ensure a clean, square cut.
• Cable Crimps: These are small metal pieces that secure the cable end to prevent fraying. You'll need a crimping tool to attach them.
• Screwdrivers: Depending on your bike's components, you might need flathead or Phillips head screwdrivers.
• Grease or Cable Lube: Applying a small amount of grease or cable lube to the cable can help it slide smoothly through the housing and prevent corrosion.
• Work Stand (Optional but Recommended): A work stand makes the job much easier by holding your bike securely and at a comfortable height.

Having these tools on hand will make the cable replacement process much more efficient and less frustrating. Remember, using the right tools not only makes the job easier but also helps prevent damage to your bike's components. With your tools ready, let’s move on to the exciting part: the step-by-step replacement process.

Step-by-Step Cable Replacement Process

Okay, guys, let's get down to the nitty-gritty. We've identified the right cable, gathered our tools, and now it's time to actually replace that frayed cable! This might seem a bit intimidating, but trust me, if you follow these steps carefully, you'll be rocking a smooth lockout in no time. We'll walk through each step in detail, so you feel confident and prepared. Remember to take your time and don't rush. Patience is key here. So, let's roll up our sleeves and get started!

1. Removing the Old Cable

First things first, we need to remove the old, frayed cable. This is a crucial step, and it's important to do it carefully to avoid damaging any components. Start by loosening the cable fixing bolt on the remote lever at your handlebars. Use the appropriate Allen key for this. Once the bolt is loose, you should be able to pull the cable head out of the lever mechanism. Next, locate the cable fixing bolt at the suspension lockout mechanism (either on the fork or rear shock). Loosen this bolt as well. Now, gently pull the cable out from the housing, starting from the lever end. If the cable is particularly frayed or stuck, you might need to use pliers to help guide it out. Be careful not to force it, as you could damage the housing. Once the inner cable is out, inspect the cable housing. Look for any signs of damage, such as kinks, cracks, or rust. If the housing is damaged, you'll need to replace it as well. To remove the housing, simply disconnect it from the cable stops on your frame. These stops are usually slotted, so you can just slide the housing out. With the old cable and housing removed, take a moment to clean the area. Use a clean rag to wipe away any dirt or grime. This will help ensure a smooth installation of the new cable. Removing the old cable is a critical first step, so take your time and be thorough. With the old cable out, we can move on to the next step: installing the new one.

2. Installing the New Cable and Housing

Alright, with the old cable out, it's time for the main event: installing the new cable and housing. This is where your attention to detail really pays off. A properly installed cable will ensure smooth and reliable lockout performance. Remember, patience is key here, so take your time and double-check your work as you go. First, if you're replacing the housing, measure and cut the new housing to the correct length. Use cable housing cutters for a clean, square cut. Compare the new housing to the old housing to ensure you're cutting it to the right length. It's better to cut it slightly longer than needed, as you can always trim it down later. Next, install the new housing by routing it through the cable stops on your frame. Make sure the housing is seated properly in the stops. Now, it's time to thread the new cable through the housing. Start by inserting the cable head into the lever mechanism at the handlebars. Then, carefully push the cable through the housing, working your way towards the suspension lockout mechanism. This can sometimes be a bit tricky, especially if the housing has tight bends. Using a small amount of grease or cable lube can help the cable slide through more easily. Once the cable is through, attach it to the lockout mechanism. Make sure the cable head is seated properly in the mechanism. Now, tighten the cable fixing bolts at both the lever and the lockout mechanism. Don't overtighten them, as this can damage the cable or the components. Tighten them just enough to secure the cable. With the cable installed, we're almost there! But before we celebrate, we need to make sure everything is adjusted correctly. Let's move on to the next step: adjusting the cable tension.

3. Adjusting Cable Tension

Okay, we've got the new cable installed, but we're not quite done yet. The cable tension is crucial for proper lockout performance. Too much tension, and the lockout might be engaged all the time. Too little tension, and it might not engage at all. So, let's dial it in just right. The first step is to test the lockout. Engage the lockout lever on your handlebars and see if the suspension locks out properly. If it doesn't, or if it feels sluggish, you'll need to adjust the cable tension. Most remote lockout systems have an adjustment barrel either at the lever or at the lockout mechanism. This barrel allows you to fine-tune the cable tension. To increase the tension, turn the barrel counterclockwise. To decrease the tension, turn it clockwise. Make small adjustments and test the lockout after each adjustment. You're looking for a smooth and positive lockout engagement. The suspension should lock out completely when the lever is engaged and release fully when the lever is disengaged. It's a bit of a Goldilocks situation – not too tight, not too loose, but just right. Once you've found the sweet spot, tighten the lock ring (if there is one) on the adjustment barrel to secure the setting. This will prevent the barrel from turning on its own and throwing off your adjustment. After adjusting the tension, double-check all the bolts and connections to make sure everything is secure. Give the cable a gentle tug to make sure it's properly seated in the lever and lockout mechanism. With the cable tension properly adjusted, you're almost ready to ride! But before you hit the trails, let's move on to the final step: trimming and crimping the cable.

4. Trimming and Crimping the Cable

Alright, we're in the home stretch! We've replaced the cable, installed it, and adjusted the tension. Now, it's time to tidy things up and make sure that cable end doesn't become a frayed mess. This is where trimming and crimping come in. These steps are crucial for a clean and professional finish, and they'll also prevent the cable from unraveling over time. First, let's trim the excess cable. Use your cable cutters to cut the cable about an inch or two past the fixing bolt at the lockout mechanism. You don't want to cut it too short, as you might need to make adjustments in the future. But you also don't want it too long, as it could snag on something while you're riding. After trimming the cable, it's time to attach a cable crimp. These little metal caps prevent the cable from fraying. Slide a cable crimp onto the end of the cable. Then, use a crimping tool to crimp the crimp securely onto the cable. Make sure the crimp is tight and won't slide off. If you don't have a crimping tool, you can use pliers, but be careful not to crush the cable. A crimping tool provides a more secure and professional finish. Once the crimp is attached, inspect your work. Make sure the crimp is securely fastened and that the cable end is clean and tidy. A frayed cable end can be a real nuisance, so this step is worth the extra effort. Finally, tuck the trimmed cable out of the way so it doesn't interfere with any other components. You can use a zip tie to secure it to the frame or another cable. And there you have it! You've successfully trimmed and crimped the cable, putting the finishing touches on your cable replacement. But before you head out for a ride, let's take a quick look at some troubleshooting tips.

Troubleshooting Common Issues

So, you've gone through the replacement process, but something's not quite right? Don't sweat it! Cable replacements can sometimes be a little finicky, and it's not uncommon to encounter a few snags along the way. Let's tackle some of the most common issues and how to fix them. Knowing how to troubleshoot can save you a lot of time and frustration. One common issue is a sluggish or non-functional lockout. If your lockout isn't engaging or disengaging smoothly, the first thing to check is the cable tension. As we discussed earlier, the tension needs to be just right. Too much or too little tension can cause problems. Use the adjustment barrel to fine-tune the tension and see if that solves the issue. Another common problem is a frayed cable end. If you notice the cable starting to fray, even after installing a crimp, it could be a sign that the cable cutters weren't sharp enough, or that the crimp wasn't properly secured. Trim the cable again with sharp cutters and re-crimp it. A frayed cable can lead to inconsistent performance and eventually cable failure, so it's important to address this issue promptly. Sometimes, the cable housing can be the culprit. If the housing is kinked, damaged, or clogged with dirt, it can impede the cable's movement. Inspect the housing carefully and replace it if necessary. Make sure the new housing is routed smoothly and isn't pinched or bent in any way. If you're still having trouble, it's always a good idea to consult your local bike shop. They have the expertise and tools to diagnose and fix even the trickiest cable issues. Troubleshooting is a key part of bike maintenance, and knowing how to address common problems will keep you rolling smoothly. Now that we've covered troubleshooting, let's talk about how to keep your new cable in top condition with some maintenance tips.

Maintenance Tips for Long-Lasting Cables

Okay, you've successfully replaced your cable, and everything's working smoothly. Awesome! But the job doesn't end there. Proper maintenance is key to ensuring your new cable lasts a long time and continues to perform flawlessly. Think of it like this: a little bit of regular maintenance can save you from bigger headaches down the road. Let's talk about some simple yet effective tips to keep your cable in top shape. One of the most important things you can do is to regularly lubricate the cable. A little bit of cable lube or grease can make a big difference in how smoothly the cable slides through the housing. Apply a small amount of lubricant to the cable, especially at the points where it enters and exits the housing. This will help prevent friction and corrosion, which can cause the cable to fray and break. Another important maintenance task is to inspect the cable and housing regularly. Look for any signs of damage, such as fraying, kinks, or cracks. If you spot any issues, address them promptly. A small problem can quickly turn into a big one if left unattended. Check the cable tension periodically and adjust it as needed. Over time, cables can stretch or settle, which can affect the lockout performance. A quick adjustment can keep things running smoothly. Keep the cable and housing clean. Dirt and grime can accumulate inside the housing and cause friction. Use a clean rag to wipe down the cable and housing regularly. You can also use a cable cleaning tool to clean the inside of the housing. Avoid using high-pressure washers near the cable and housing, as this can force water and debris inside. By following these simple maintenance tips, you can extend the life of your cable and ensure smooth and reliable lockout performance for years to come. And with that, we've reached the end of our comprehensive guide! You're now equipped with the knowledge and skills to replace your remote suspension lockout cable with confidence.

Conclusion

So, there you have it, guys! We've covered everything from identifying the right cable to troubleshooting common issues and maintaining your new cable for the long haul. Replacing a remote suspension lockout cable might seem like a daunting task at first, but with a little knowledge and the right tools, it's totally achievable. Remember, the key is to take your time, be patient, and pay attention to detail. Accurate identification of the cable type, proper installation, and regular maintenance are all crucial for a smooth and reliable lockout system. We've walked through each step in detail, so you can feel confident tackling this project on your own. And the satisfaction of knowing you've done it yourself is pretty awesome, right? Plus, you've saved some money by not having to take it to a bike shop. So, go ahead, grab those tools, order that new cable, and get your suspension lockout working like a charm. And if you ever run into any snags, remember this guide is here to help. Happy riding, and may your suspension always be locked out when you need it to be!