2008 model clutch cable snapped @ 17,800 miles. Replacement?

[CZroe]

I was less than a mile from home and there was no traffic at 1:00AM when it happened so I used clutch-less shifting to get home. I had to be back at work in four hours and I was already on a pretty serious sleep deficit so I wasn't able to look at the routing and see if it was something I could easily do myself with the part.

Anyway, is this something a dealer will have to order specific to the bike or are they able to select a standard cable of the right specifications? I can't really afford to have the bike towed and it's my only transportation, so I'm hoping that it's something I can take care of myself in one day with locally-available parts (I got a ride with the boss this morning).

[CZroe]

Perhaps someone can answer me this: What major parts stores might be local to San Diego? Neither dealer has one.

[FrugalNinja250]

About the only thing you can do is get on the phone and start calling Kawasaki dealers. Also check the independents, and see if anyone close has a parts bike they'll sell you a cable off of.

This is why I pre-ordered replacement cables (2) to keep in stock, one installed on the bike parallel to the old one and one in a box at home.

Best of luck to you.

[CZroe]

Originally Posted by FrugalNinja250

About the only thing you can do is get on the phone and start calling Kawasaki dealers. Also check the independents, and see if anyone close has a parts bike they'll sell you a cable off of.

This is why I pre-ordered replacement cables (2) to keep in stock, one installed on the bike parallel to the old one and one in a box at home.

Best of luck to you.

I already called the dealers... No dice. I'll try mom 'n' pop places next.

The parallel idea sounds like a smart one! I guess you'd be the one to ask this then: How involved is the installation? Will I have to take anything off other than the side fairings? Do the replacements include a new rubber piece (mine rotted in pieces)? Thanks!

Your precaution makes it appear like you expect it to happen pretty often. Has this happened to anyone else on the forums yet? I couldn't find any.

[Ichiro]

Replacing the Clutch Cable DIY here:
http://www.ninjette.org/forums/showthread.php?t=16000

Lube and Adjust the 250R Clutch Cable:
http://www.ninjette.org/forums/showthread.php?t=10016

[FrugalNinja250]

Originally Posted by CZroe

I already called the dealers... No dice. I'll try mom 'n' pop places next.

The parallel idea sounds like a smart one! I guess you'd be the one to ask this then: How involved is the installation? Will I have to take anything off other than the side fairings? Do the replacements include a new rubber piece (mine rotted in pieces)? Thanks!

Your precaution makes it appear like you expect it to happen pretty often. Has this happened to anyone else on the forums yet? I couldn't find any.

It's not that I expect it to happen pretty often, it's just that the consequences of it happening can be fairly bad, such as being in heavy stop and go traffic, and compared to the consequences the cost of the cable is fairly cheap. I've got an '06 so my installation is different, but basically you likely will have to pull the fairing and the tank.

[Rexbo]

Originally Posted by FrugalNinja250

It's not that I expect it to happen pretty often, it's just that the consequences of it happening can be fairly bad, such as being in heavy stop and go traffic, and compared to the consequences the cost of the cable is fairly cheap. I've got an '06 so my installation is different, but basically you likely will have to pull the fairing and the tank.

It takes about an hour, and I removed only the right side fairing for ease of install, but it could be done without.

[addy126]

Originally Posted by FrugalNinja250

This is why I pre-ordered replacement cables (2) to keep in stock, one installed on the bike parallel to the old one and one in a box at home.

Now there's a thinker!!!! I'm gonna due the same, cuz you just never know. Thanx Frug. Some of the simplest things are always overlooked......

[spicy mayo]

This is definitely something specific to the bike, so your gonna be picking it up from the dealer if not online from somewhere like ron ayers/bike bandit etc.

http://www.ronayers.com/Fiche/TypeID.../Group/Cables_

Check out there microfiche you can order any part of the bike. I usually get my stuff within a week from them.

[CZroe]

Well, guys, I got the original cable repaired at Clairemont Cycle Supply in San Diego. The new piece at the end doesn't have the same kind of plastic on the lever end (doesn't feel like slippery Teflon like the original), so I don't know how long it'll hold out for me, but I'm sure it'll get me to work tonight. I'm still going to order a new replacement.

Anyway, the clutch lever feels effortless, which concerns me. When the bike was new it was stiff enough to cause a sore hand due to untrained muscles. The way it is now doesn't feel like it would ever cause discomfort. When I look at the arm the the cable pulls, it appears ever so slightly farther out than I remember (I did have to lift and reorient a couple times when I couldn't just turn it back I to place). Everything seems to function fine.

The old cable frayed and broke right out of the lever's anchor piece with very little left inside it. There were chunks of metal from the anchor piece all I the white plastic sheath and a half-circle cone of space around the point that the cable attaches as if it were pulled to different sides to break off chunks from the piece it goes into.

Originally Posted by addy126

Now there's a thinker!!!! I'm gonna due the same, cuz you just never know. Thanx Frug. Some of the simplest things are always overlooked......

Well, I realize that it would be kinda tight on a current generation Ninjette after de- and re- routing mine. You could zip-tie it and generally run beside it but it's thick, stiff, and seemingly "spring-loaded" to return to its original shape, so I'm not really sure how you can properly kink the ends out of the way.