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HOW TO - Cable Replacement
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HOW TO - Cable Replacement
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cane_prevost



Joined: 23 Mar 2010
Posts: 215
Location: Portland Oregon

Post Reply with quote
Attempting a clutch cable replace soon. Will photograph the carnage and write it up.
Wed Aug 07, 2013 7:29 am View user's profile Send private message
cane_prevost



Joined: 23 Mar 2010
Posts: 215
Location: Portland Oregon

Post Cluch cable how to Reply with quote
1. Take off the mirrors and headlight ring.

2 Remove the 4 screws that hold the headset in place.

3 Look directly under the engine and you will see the clutch arm and cable. If you are lucky the pinchbolt is still there.

4 Go ahead and pull the cable out and get the pinch bolt off the old cable.

5 Depress the handle and remove the other end of the cable from the lever.

6 Here's the outer cable housing with the end cap on it. Don't lose the end cap as it's not secured in place.

7 You should be able to run the new cable all the way through the housing and out the back end. Then attach it to the hand lever. It should just twist into place at the hand lever.
Below you can see the outer housing and how it routes to the clutch lever in the headset. It's the gray cable.

8 Put the pinch bolt on the cable and slide up to the clutch arm. The arm will have about an inch of play as you push it towards the front tire. Push it all the way to the front tire and then tighten your pinch bolt down there. This will be very close to just right. Tighten it down and test. You should have just a hair of play in the clutch before it engages. Any adjustments from here will be tiny ones in either direction. Below you can see the pinch bolt and clutch arm from under the engine.


That's about it! Pretty easy. Oh, make sure you grease your cable before running it through the housing. It'll last longer.
Sun Aug 11, 2013 11:10 pm View user's profile Send private message
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