Author Topic: Broken clutch cable in the middle of no where (Read 10637 times)

evanwellsk75 · « **on:** March 08, 2020, 07:07:45 PM »

Hey my clutch cable snapped in the middle of marin county in point reyes. This tiny town on a sunday doesnt have a garage open for another 2 days. Its such a simple thing to cause a conundrum but here we are, is there anyone around that can bring me one. Or does anyone have any ideas?

Thanks

daveson · « **Reply #1 on:** March 08, 2020, 07:40:12 PM »

In first gear, push the bike and start it. Time to practice clutchless changes, like truckies do all over the place.

Laitch · « **Reply #2 on:** March 08, 2020, 07:45:55 PM »

Quote from: evanwellsk75 on March 08, 2020, 07:07:45 PM

Hey my clutch cable snapped in the middle of marin county in point reyes. . . . does anyone have any ideas?

Here's a time-tested solution.

daveson · « **Reply #3 on:** March 08, 2020, 07:59:57 PM »

Yep, that's way safer.

herseyb · « **Reply #4 on:** March 08, 2020, 08:32:53 PM »

that johnny motobrick ace fix saved my ass one day. Rode it for like a month after I got the replacement cause it just worked...

johnny · « **Reply #5 on:** March 08, 2020, 09:04:41 PM »

greetings...

once i hooked a bungee to the clutch arm by the exhsust... pulled on it to change gears... that is when i made the kit... and now carry the kit and a spare oe...

rode all the way from johnston ridge observatory at mt st helens to hillsboro... 130 miles... 2up... tugging on the bungee...

if you wanna take the cable out of the jacket you can just tug on the cable... look... take a deep breath... step away... figger it out... go getts something you can tug on...

j o

evanwellsk75 · « **Reply #6 on:** March 09, 2020, 05:51:48 PM »

Hey, sorry about the radio silence my phone died and I camped out last night. I got the clutchless gear shift down and have put about 30 miles behind me, I tried using the pulley method when it happened but the lever is tighter then hell, or I wasnt pulling on it hard enough. Any ideas why that might be? Did I possibly burn out the clutch somehow?

volador · « **Reply #7 on:** March 09, 2020, 05:59:05 PM »

Quote from: evanwellsk75 on March 09, 2020, 05:51:48 PM

Hey, sorry about the radio silence my phone died and I camped out last night. I got the clutchless gear shift down and have put about 30 miles behind me, I tried using the pulley method when it happened but the lever is tighter then hell, or I wasnt pulling on it hard enough. Any ideas why that might be? Did I possibly burn out the clutch somehow?

You smell any smoke? From the clutch I mean? If not pull on that pulley harder

evanwellsk75 · « **Reply #8 on:** March 09, 2020, 06:07:10 PM »

I havent smelled anything abnormal, I burnt out a clutch before by accidentally over tightening it so I was checking pretty frequently on any acrid smells coming from it. Though I just tried again, hard as a rock. Im starting to think this might be a larger problem than just the cable?

evanwellsk75 · « **Reply #9 on:** March 09, 2020, 06:20:43 PM »

Op! Sidestand was the issue. Wire and screw clamps here I come!

Laitch · « **Reply #10 on:** March 09, 2020, 06:44:45 PM »

Thanks for these updates. Keep them coming.

evanwellsk75 · « **Reply #11 on:** March 10, 2020, 03:12:28 PM »

Still stuck in santa rosa, no hardware stores seem to have these hillman fasteners so im calling around to repair joints to see if theyd let 2 go. As of now no luck

Martin · « **Reply #12 on:** March 10, 2020, 04:23:45 PM »

I've been carrying a spare clutch cable for the last 20 plus years. It's been used twice, but not on my bike. I do have a tendency to carry a pretty good selection of spares. To be honest besides a couple of flat tyres and the two times I had to use the test light nothing else has been used on my bike. Murphy's Law number 221 is nothing you carry will ever fail. Not shown is spare throttle and clutch cable and a newly added HES. The AM/FM radio has been replaced with wireless ear phones linked to my GPS helmet lock and cable has been replaced with a more compact version.
Regards Martin.

Tools in tail.png (61.06 kB . 768x576 - viewed 472 times)

Tools in Topbox.png (52.09 kB . 768x576 - viewed 456 times)

koapono · « **Reply #13 on:** March 10, 2020, 05:32:34 PM »

when you buy replacement cable, buy two.
run the "spare" alongside the new one, grease up the exposed parts and wire-tie the ends out of the way.
you'll never snap another cable again, provided you lube the ends once a year or so.

volador · « **Reply #14 on:** March 10, 2020, 06:01:32 PM »

more like

CLUTCH CABLE KIT.jpg (31.91 kB . 400x400 - viewed 428 times)

Martin · « **Reply #15 on:** March 10, 2020, 06:20:12 PM »

I always lube all my cables with a PTFE lubricant which is compatible with the Teflon lined OEM cables. Some non PTFE based lubricants are not compatible and will actually degrade the lining faster than applying no lubricant at all. WD40 is not a cable lubricant.
Regards Martin.

evanwellsk75 · « **Reply #16 on:** March 10, 2020, 06:25:53 PM »

Got a used one off a fella here in santa rosa, as far as an emergency kit goes. I had one but decided to store it away in Denver for the winter while I was over seas. Didnt think Id be touching the bike again, but I didn't have a spare clutch cable in that either. Definitely gonna add it when I collect all my things once again.

evanwellsk75 · « **Reply #17 on:** March 10, 2020, 08:55:07 PM »

Hey so I installed the cable, all is seemingly alright though is doesnt seem like the clutch is engaging fast enough- it feels loose (it wont engage until the lever is almost all the way out). Il walk through my procedure and maybe someone can tell me where I screwed up.
I installed it along roughly the same path as the old one (I couldnt get the metal tube end on the handle side through a piece between the radiator and frame so I went over it.
I lubed up the handle side barrel point. (This is surely why I snapped it in the first place)
I slacked the handle side all the way then adjusted until I had 2.96 in on the lever near the transmission.
I then tightened the transmission adjust bolt just until I had resistance, then stopped.
I readjusted the handle side adjustment screws.

And here I am. It works, but It makes me nervous on hills and for longevity for the clutch.

johnny · « **Reply #18 on:** March 10, 2020, 09:19:08 PM »

greetings...

is this moto oe or delooped... poast up some photos of this moto and include the clutch lever mechanism at the handlebar...

j o

evanwellsk75 · « **Reply #19 on:** March 10, 2020, 09:35:27 PM »

Here ya are johnny

Martin · « **Reply #20 on:** March 10, 2020, 09:44:48 PM »

You can by this tool off Tills or make one out of a piece of 75mm box.
Regards Martin.

Clutch cable set tool 1.jpg (74.85 kB . 768x576 - viewed 451 times)

Clutch cable set tool 2.jpg (56.23 kB . 768x576 - viewed 418 times)

evanwellsk75 · « **Reply #21 on:** March 10, 2020, 09:57:25 PM »

Hey martin thanks, ive fashioned something similar out of some wire

volador · « **Reply #22 on:** March 10, 2020, 09:59:21 PM »

Looking good. It is measuring tool for the 3 inches/75mm at the clutch arm/lever
If you have a doubt here is the procedure

http://www.motobrick.com/index.php/topic,13203.msg117628.html#msg117628

evanwellsk75 · « **Reply #23 on:** March 10, 2020, 10:08:15 PM »

Right right, smart way to measure around the grommet. Its all well and good, ive measured it a half dozen times now and still the clutch doesnt engage, though theres little freeplay and its quite hard to pull in. I lubed it up some more and its easier to pull in.

evanwellsk75 · « **Reply #24 on:** March 11, 2020, 12:51:46 AM »

Yeah I have zero free play in my handle bar lever, Ive tried adjusting it both at the handle bar and tranny case. Does this make any sense? The cable came off a k100 so my only thought is maybe its sized differently or the cable was already pretty stretched. But that doesnt really explain the lack of slack coupled with the minute friction zone.

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Author Topic: Broken clutch cable in the middle of no where (Read 10637 times)