Clutch Cable Replacement Trick/Tip

Mechanikrazy · November 26th, 2016, 12:10 AM

Maybe this is obvious, but I did not see anyone post about replacing the clutch cable without pulling the fairings. When I did a search, it seemed like people are following the manual, which includes removal of the mid-fairing (also means dropping the lower fairings). If you happen to be supremely lazy like I am, there is a much faster way.

With this method, all you have to do is loosen the two ends of the clutch cable.

From the top, lever-side (this trick has to be done from the top; explained below), just duct-tape the end of the new cable to the top end of the old cable. It must be tip to tip though, due to size constraints. What I did is helically wrap the cables for about a foot (6 inches of each cable). You can probably get away with less, but duct tape is cheap and I wanted to make sure the cables wouldn't pull out.

Then just push/pull the cable from both ends to pull the cable out from the bottom side. There is only one hiccup point--why you have to pull downwards--which is a cable holder at the front right side of the gas tank after the clutch cable has passed through the frame. The two bolts at the bottom of the clutch cable are really tight fits. You have to make sure the sides of the bolts are parallel to the sides of the holder. But you can pull it through with the right angle.

All that is left is to reattached the cable at both ends. This simplifies your clutch cable replacement immensely. Hope this saves time for some of you. I tried to take a video of it, but my old GoPro sucked with low-light/contrast.

Alex · December 3rd, 2016, 09:04 PM

Triple Jim · December 3rd, 2016, 09:50 PM

Excellent idea! I've done things like this with wiring in houses, etc., but I don't remember applying it to motorcycle cables.

dcj13 · December 3rd, 2016, 10:41 PM

The method you describe also assures correct routing.

Mechanikrazy · December 3rd, 2016, 10:48 PM

Quote:

Originally Posted by Triple Jim

Excellent idea! I've done things like this with wiring in houses, etc., but I don't remember applying it to motorcycle cables.

Same. I've done the fishing line method before, but working in an apartment garage (with a no repairs policy) has made me try to shortcut as much as possible. Haha.

Next job, fiberglass patching.... Hah

November 26th, 2016, 12:10 AM	#1
Mechanikrazy ninjette.org guru Name: Al Location: Orange County, CA Join Date: Dec 2015 Motorcycle(s): Thruxton R, R6 450 triple, EX300 (sold) Posts: 263	Clutch Cable Replacement Trick/Tip Maybe this is obvious, but I did not see anyone post about replacing the clutch cable *without* pulling the fairings. When I did a search, it seemed like people are following the manual, which includes removal of the mid-fairing (also means dropping the lower fairings). If you happen to be supremely lazy like I am, there is a much faster way. With this method, all you have to do is loosen the two ends of the clutch cable. From the top, lever-side (this trick has to be done from the top; explained below), just duct-tape the end of the new cable to the top end of the old cable. It must be tip to tip though, due to size constraints. What I did is helically wrap the cables for about a foot (6 inches of each cable). You can probably get away with less, but duct tape is cheap and I wanted to make sure the cables wouldn't pull out. Then just push/pull the cable from both ends to pull the cable out from the bottom side. There is only one hiccup point--why you have to pull downwards--which is a cable holder at the front right side of the gas tank after the clutch cable has passed through the frame. The two bolts at the bottom of the clutch cable are really tight fits. You have to make sure the sides of the bolts are parallel to the sides of the holder. But you can pull it through with the right angle. All that is left is to reattached the cable at both ends. This simplifies your clutch cable replacement immensely. Hope this saves time for some of you. I tried to take a video of it, but my old GoPro sucked with low-light/contrast.
	3 out of 3 members found this post helpful.

December 3rd, 2016, 09:04 PM	#2
Alex ninjette.org dude Name: 1 guess :-) Location: SF Bay Area Join Date: Jun 2008 Motorcycle(s): '13 Ninja 300 (white, the fastest color!), '13 R1200RT, '14 CRF250L, '12 TT-R125LE Posts: Too much. Blog Entries: 7	__________________________________________________ Montgomery Street Motorcycle Club / cal24.com / crf250l.org / ninjette.org ninjette.org Terms of Service Shopping for motorcycle parts or equipment? Come here first. The friendliest Ninja 250R/300/400 forum on the internet! (especially Unregistered)

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December 3rd, 2016, 09:50 PM	#3
Triple Jim Guy Who Enjoys Riding Name: Jim Location: North Carolina Join Date: Jul 2016 Motorcycle(s): Ninja 250 Posts: A lot. MOTM - Oct '18, Aug '17, Aug '16	Excellent idea! I've done things like this with wiring in houses, etc., but I don't remember applying it to motorcycle cables.

December 3rd, 2016, 10:41 PM	#4
dcj13 Participant Name: Dave Location: South of Seattle Join Date: Oct 2012 Motorcycle(s): '94 K75 std Posts: Too much. MOTM - Aug '15	The method you describe also assures correct routing.