Clutch lever cable adjuster for SV650S K4

[TimTucker]

In a quite incompetent attempt to fit a new clutch cable to my SV -- which, according to Sid Squid, I probably didn't need to buy -- I have managed to snap the threaded cable adjuster that feeds into the clutch lever assembly.

On the bright side, I have at least managed to remove the whole thing from the lever assembly, so it's just a new threaded, slotted adjuster "bolt" I need, if you know what I mean!

If someone has got one I can have, that would be great. If someone can recommend me a place online to buy one, that would also be good.

Advice on how to properly locate the cable at the front of the bike so that it doesn't do this again would also be appreciated! In the meantime, I'm going back to look at the thread on how to adjust your clutch properly . Clearly there's something there I've not understood.

I put a new clutch cable on just this afternoon..

I'm not going to try and immagine how you snapped that.. but..

Take the clutch cover plate off (plastic bit near gear lever) 3 bolts.
Unbolt the end of the clutch cable from the mounting point. You wont be able to get it out, but undo the bolts as far as they go so you've got loadsa slack (you can screw the bottom bolt off all the way onto the cable).
Then, up at the handle bar end you should hav ea bit of play in the cable now..
Pull that rubber sheath back (oOo er)
screw the adjuster bolts all the way in so they are as close to the lever as they will go, each bolt has a slot in it. line them both up so they are facing the front of the bike.
pull the sheath of the cable out of the adjuster bolt, if it's still in there. Then pull the cable fowards. there's a slot it will come out of if you've got the bolts ligned up right.
The cable should not be attached to your clutch lever, angle the cable so it's pointing fowards at 90 degrees to the lever and push it down. It should pop out of the lever.

Simples.

A few more top tips..

The other end of the cable is locked into the clutch lever mechanism. (engine side of things now)
You should have enough slack on the cable now to take the threaded bolt out, just pull the sheath up and slide the cable through the slot.
Then you need to un bolt the pivot for the clutch lever. Two bolts top and bottom.
Take them out, now hold the lever and bolted mount bit in your hand together. Get rid of the spring and the spring holder. Get some wire / tape and tape the lever bit to the bracket bit so they can't come apart.
Because if you don't, they will, then you'll spend ages looking for ball bearings and putting that back together.

On the lever at the other end, there should be a little tab that's pushed in, holding the cable in place, you'll need to bend this back.
The way I did it was to cut the cable a bit above where it's mounted and take the whole assembly to the bench and hammer it out with a flat head screwdriver.

Once that's out everything should be ready to take the new clutch cable.

Now, rather than taking the tank off to thread the new clutch cable, I cheated.
Get some string, and tie it around the engine side of your old clutch cable.
Pull the clutch cable (with string) out of the handle bar end.
Remove old cable, tie string onto new cable and pull it back towards the engine.

Then reverse the above.

Put the engine side back in it's lever and hammer the tab down (I rested the assembly on an axle stand and gave the tab a good whack.
Bolt the lever you taped / wired up pack on with the spring etc.
Put the threaded bit through the slot on the engine end. Dont do the bolts up.
Then put the lever end back in, reverse of how it came out.

Then tension up the threaded end.

I adjusted it so about the first half of the clutch lever travel was taking up slack. then adjusted the rest on the bar end.

Good luck..

Had a thought about your other dilemma..

http://www.pro-bolt.com/motorcycle/s...html?cat=35504

HTH

[TimTucker]

Thanks for that, especially the link to the ProBolt website. It's a real festival of anodised tat on there, isn't it? But I've ordered myself a lovely new cable adjuster in "tasteful" grey.

As for how I broke it, my big struggle has been getting the handlebar end of the cable to sit properly, with its curved sleeve. I just couldn't get it to sit right with the lever, so it ended up pulling and breaking the adjuster.

I think I'm going to spend time getting the cable into the clutch level and everything aligned correctly before I even attempt to get the other end fastened down by the sprocket. I'm sure I have it seated where the old cable was routed by the headstock, but it's been a struggle so far.