Noob needs to replace clutch cable
 

Hi,

I adjusted my clutch cable a while ago as it felt spongy. Today coming back from work it went really slack, and i could hardly change gear. I went to tighten it again when i got home, but noticed that the adjustment was right at the end, so i think the cable need changing. Thing is im a noob and could do with a idiots guide please :smt045

Sorry if this has been covered before and thanks on advance!

Re: Noob needs to replace clutch cable
 

Right at the end where? At the lever end? If so then you need to adjust it at the clutch end. If the clutch end, then yes a new cable is needed.

Do a search for clutch adjustment by sid squid (Advanced tab in the search window) if you need to adjust the cable end.

Also check it out for fitting a new cable. Its pretty simple. Loosen off the cable at the the clutch end, remove cable form bike (Making note of its path through the bike), then from the lever.

Re: Noob needs to replace clutch cable
 

hang on a minute!

have you done the Worm Drive Adjustment?

(i'm no good at explaining this one....)

Re: Noob needs to replace clutch cable
 

At both ends:D i tightened it at the clutch end last time, and when i checked it this morning, it was only about a thread away from the end of the bar end. The locking nut had worked its way loose and i thought it might be that at 1st, but when i tightened that up it was still loose.

Re: Noob needs to replace clutch cable
 

is the clutch operation smooth, or is it sort of notchy? if notchy, get a new cable, its about to go *ping*

Re: Noob needs to replace clutch cable
 

Its neither. When you pull it in its sooooooo slack, theres no or very little resistance.

Re: Noob needs to replace clutch cable
 

i had the same problem on my hyo 125, id get a new clutch cable personally just for peace of mind.

Re: Noob needs to replace clutch cable
 

We swapped out Pepin's clutch cable in about 10 mins last week. Easy guide:

1) Adjust the cable at the lever to be as slack as possible, to reduce tension on lever.
2) Undo the bolt that runs through the lever. Make sure you don't lose the nut on the other side.
3) Push the lever forwards and it will rotate out. Pull out the cable through the groove so the lever-end is free.
4) Undo the 3 bolts on the the front sprocket cover and take it off.
5) Undo the bottom bolt on the clutch-end adjustment, then pull the adjuster up and out of its mounting socket. This should leave you with a cable that's only held in by a metal tab inside the small metal U-shaped socket attached to the worm-drive.
6) This can be a bit tricky, but you need to push the metal blob out of the U-shaped cradle, then pushcable down into it. This will let you slide it out by swinging the tab through the other side of the U-shaped cradle. This sounds complicated, but it's easy once you see the setup!
7) You've now got a completely loose cable.

At this stage, there's 2 methods of changing this for your new cable.

8)a) Take off the side-covers of the bike, the rider's seat and prop the tank up. Withdraw the old cable, taking careful note of how it routes through the frame and down to the worm-drive. Route it through in exactly the same way, then drop the tank, seat on and side covers on.
8)b) Cut the round metal piece off the lever-end of the old clutch cable. Slide the curved metal tube off. Duct-tape this end to the worm-drive end of the new cable. Carefully pull the old cable through the frame, pulling the new one with it. Make sure you take off the metal bit on the old clutch cable first, though, or it'll just get stuck!

9) Attach clutch cable at both ends by doing sections 6 to 1 in reverse. Adjust, enjoy great feeling clutch!

Re: Noob needs to replace clutch cable
 

OK,

I've replaced the old clutch cable with a new one. I took a few pics and think i routed it the same way, coupled it all back up and its still the same. The lever is really slack, the clutch side of it is barley moving the spring.

Any ideas?

Re: Noob needs to replace clutch cable
 

Is it disengaging the clutch fully when you pull it?
It might be worth adjusting the worm drive as above.