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| Tech ALL bikes: "Generic" tech questions and answers. Maintenance, general discussions etc. |
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#1
21 Aug 2009
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Installing a new clutch cable.
Hi there. Was riding through town the other day and my inner clutch cable snapped. I went to High Peak Motorcycles in Derbyshire for a new inner cable and went home to do a bit of fixing. Unfortunately I thought I knew it all and it took me a while to realise there were two adjusters to sort! The nipple that holds the cable to the clutch arm was less then perfect, so I ordered a brand new complete cable which should arrive tomorrow.
My clutch arm sits ontop the crankcase, this is where the bottom of the cable slots in. 10cm up there is an adjuster. The cable then goes all the way up to the handlebars with an adjuster there. The clutch itself is fine. So just to check; After I tape the new cable to the old one and pull it through, I will connect at the handlebars with the 'free play' adjuster set to minimum. Il then connect at the engine onto the clutch arm and then set the adjuster at that end to minimum level too. So both adjusters are at '0' rather than at full stretch. From there I will set the free play adjuster so that the clutch lever on the handlebars has a pennies width of free play. I will then tighten at the engine side (if needed) so the cable pulls in the clutch arm successfully. Does this sound OK to every one? Thanks. 
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#2
21 Aug 2009
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Sounds about right to me.
You may find the arm on top of the engine has sprung past the fully engaged point, in which you'll need to put a few turns on the bottom adjuster. A pair of mole grips on the lever sticking out of the engine usually gives enough leverage so you can take up most of the slack by hand rather than 1/6th of a turn at a time. Andy
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#3
21 Aug 2009
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Thanks Andy. Yeah there is a bit of slack needed taking up in the clutch arm but nothing too much. Looking forward to being able to move tomorrow! After I have cut the grass of course....
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