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| Clutch Cable - 604 Rotax | |
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| Tweet Topic Started: Nov 6 2012, 02:01 PM (2,581 Views) | |
| sullivj | Nov 6 2012, 02:01 PM Post #1 |
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Viscount
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Had my first ride to work yesterday on my 'finally' road legal bike. I noticed last night that the cable is fraying at the nipple. Not long before it goes SNAP I'd imagine. In advance of that happening, I've just been to Vernhill to collect a new one: http://www.venhill.co.uk/ Any tips on replacing it? I've heard that getting it out at the clutch end, can be a pain. Thanks in advance. |
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| Monty | Nov 6 2012, 02:10 PM Post #2 |
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Charlie Big Banana's
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Cuz will be the chap to help. I have never had to change one as yet, It may be possible to do so with out removing the clutch cover. |
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If it aint sharp I can play with it My Utube Channel, lots of bike vids here. Subscribe if you likehttp://www.youtube.com/user/choppermark?feature=watch
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| BK350 | Nov 6 2012, 04:40 PM Post #3 |
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Marquess
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I´m not Cuz, but will try it.... ;) Removing the cable on the handlebars should be quite easy, on the clutch side its the following: Screw out the two plastic caps on the clutch cover (take care of the two O-rings). In best case you can push down the cable so it gets free from the the release cam in the inside(where it is mounted).You can see this when you`re looking into the hole of the clutch cover. If not, use a small pointed pliers to remove it from the release cam. Now you can pull out the old cable. Installing the new one is the same in reverse order. Using the small pointed pliers again is the best if you`re not a surgeon, cause you have to mount it in the release cam. Sometimes you manage it with the first try, sometimes you need half of an hour (my experience :rant:) For fine adjustment of the clutch you will need a flat screwdriver and an 11mm socket wrench (normally included in the tool box). Before the following I do adjust maximum play on the clutch lever side. Hold the screw with the screwdriver and loosen the nut. Tighten the screw slightly until you feel it touching the thrust hub, then something between 1/8 to 1/4 turns back and tighten the nut with the wrench. After that adjusting the play on the clutch lever. Hope its understandable...... Chris |
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| Monty | Nov 7 2012, 10:19 AM Post #4 |
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Charlie Big Banana's
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Cheers BK, now I know what to do
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If it aint sharp I can play with it My Utube Channel, lots of bike vids here. Subscribe if you likehttp://www.youtube.com/user/choppermark?feature=watch
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| Cuz | Nov 7 2012, 07:44 PM Post #5 |
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God
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Thats explained much more clearly than I could of done :D make sure theres no crap in the cable housing on the case and the o'ring on the cable as this is a potential oil leak (often mistakenly thought to be a base gasket leak) |
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| sullivj | Nov 7 2012, 08:29 PM Post #6 |
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Viscount
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Thanks very much for your replies chaps. It's likely to be Sunday before I can get this done. I will take some snaps and write up as usual to help anyone else that needs to give this a go. |
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| sullivj | Nov 8 2012, 07:33 PM Post #7 |
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Viscount
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Well, I couldn't wait for Sunday - Just been out in the garage. Here's the new one I got from Venhill. For an extra £1.80 ish, I got a new rubber boot for the lever end too. ![]() Thanks to your help chaps - it was an easy job. I manage to get the nipple into the actuator arm on the 2nd attempt :) Not many pictures I can add, apart from the 20p trick, which shows the plug you need to take out to see the actuator lever (towards the top of the hole, but unseen in the photo). ![]() Getting it into the lever at the top end was a bit tricky. I ended up taking the lever apart to get the nipple in at that end. Anyway it's done now. I'll run it out when I get the chance and see if needs any adjustment - hopefully not. Although, if it does, I do have the adjustment spanner that I purchased from Force M/Cs for a tenner. Here's the one I took out - it was waiting to fail....
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| BK350 | Nov 9 2012, 11:48 PM Post #8 |
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Marquess
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Hi sullivj, noticed on your new cable that the lever sided nipple has a smaller diameter as the lever itself... don`t be surprised when you install it. Works although the more narrow measurements; only thing can happen is, that the lever is wearing out more sooner. Away from that you can pick up a bigger nipple from your local bike dealer and modify it by making a slot in into it to make it matching for the lever (at least I had this problem at my 2001model with the adjustable clutch lever, maybe you have different one). Chris |
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| sullivj | Nov 10 2012, 08:59 PM Post #9 |
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Viscount
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You're right BK - the new niplle at the clutch end is smaller than the old one. That was well spotted!! Well, the old one actually had a sleeve to enlarge the nipple, but it couldn't be swopped over. So. I'm running with the smaller nipple. It seems to work OK. |
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