Fixing a Broken Clutch Cable on a Motorcycle By Walter F. Kern Part of a Series, Motorcycle Problems and Solutions Our Motorcycle Views Forum members often seek solutions to important repair and maintenance problems from the experts on the forum. Many of our best experts are professional motorcycle mechanics or those who have done their own mechanical work and have seasoned practical experience. I've decided to publish a series of motorcycle problems submitted to our forums and their solutions. Only the most universal problems will be addressed so most readers will see a problem that may be affecting them. I'll state the problem exactly as posed by a reader and then give a solution based on responses given by our most knowledgeable forum members. Problem from Dollarsforri:
Yesterday, I wanted to start it because I didn't want it freezing to death. Anyway, I noticed the break in the cable was right by the clutch lever. Can't I just reuse the cable? The only thing that appears wrong with it is that the end that goes into the clutch lever has a big split end. My shop manual doesn't say how the cable connects to the clutch lever. Is the thing still salvageable in the first place? If so, how does the cable connect to the lever?" Solution by Hondamototech:
To replace the cable, loosen the adjuster at the motor and at the lever all the way (that's in, not out) and then remove the cable. The motor end probably has a ball too that goes into the lever. Just unhook the cable sheath from the cable stop on the bottom and then just pull it out of the clutch lever perch on top as it's already broken there. Take the ball out of the lever by rotating it until the broken piece of cable lines up with the slot in the lever. Then just push the ball out. With the new cable, route it where the old cable went and then hook up the bottom first making sure you turn the adjustment sleeve all the way in. Then put the ball into the eye on the clutch lever, turn the ball so the new cable fits through the slot on the lever, and then pull on the sheath to get the cable to go through the slot on the perch. Once that is done, then screw the sleeve adjuster all the way into the perch. (Some cables only have an adjustment sleeve on one end, usually the lever end.) After the cable is on, adjust the clutch AT THE BOTTOM FIRST. That way you can make fine adjustments at the top while riding. The new cable will stretch a little so be prepared to adjust it again after a few hundred miles." If you have a motorcycle repair or maintenance problem that you feel has wide appeal, just post your problem in the Motorcycle Repair Corner of the Motorcycle Views Forum. Only the most universal problems and the best solutions will be considered for inclusion in this series. More Motorcycle Problems and Solutions
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