Clutch Wire Broke, help?

[DesmoBM]

Hi,
I've been reading the forums quite a bit, since I got my bike about 3 months ago. Just experienced my first problem. My clutch wire broke, as in it snapped near the lever and it looks like it's an easy fix, but does anyone have any advice in going about replacing it.

Is the best option, just to go to the local cycle shop and pick up a replacement and do it myself?

Thanx for the help.

[pixelmonkey]

Is the best option, just to go to the local cycle shop and pick up a replacement and do it myself?

thats the right / only way to do it.

cable replacement using a motion pro, or other aftermarket brand will run you around $20.

for replacement, when removing the old cable, be sure to feed the new one in the exact same way / place. best bet would be to remove the gas tank to make things easy.
chris<pixelmonkey>

[Kerry]

Yep, definitely do it yourself.  It's not too hard.  Just so you know in advance, you'll need to:

* Remove the gear shift lever (10mm wrench, IIRC)

* Remove the 5 bolts for the left case cover (~8mm socket) and pull the cover.

* Undo the mounting nut where the cable enters the case, and unscrew the threaded cable housing from the case.

* Thread the new cable in, right alongside the old cable.

* Bend the metal tab that captures the ball end of the old cable, put the new cable end in place, bend the tab back.

* Adjust the tension, leaving some "adjustability" on either end of the cable.[/list:u]I skipped over removing the tank.  I think I did the job without that step, but that forced me to thread the new cable over the frame cross member because I couldn't make the bend.  I wish I had taken the tank off and done it "right".

cable replacement using a motion pro, or other aftermarket brand will run you around $20.

As I recall, the OEM unit was in the same ballpark price-wise.

To keep the same thing from happening prematurely in the future, keep your cable lubed!

[Bob Broussard]

You'll need to remove the shift lever off the shaft. Then take the side case off (8mm socket). The cable is held in place by a metal tab on the mechanism inside the cover. Bend the tab to remove the cable. Install new cable and bend tab back.
Re-install case, but leave it loose until the cable is connected to the lever.
Then tighten the bolts and put the shift lever back on.
Adjust the slack at the lever as needed.

[Dom]

The guy that had my XL600r before me used a clutch cable that was too short and he made up the extra length with a piece of a wire coat hanger.  I never changed it the whole time I owned the bike.  Everyone who looked at my bike commented on it.  But you know what they say: "If it ain't broke, don't spay or neuter it."  :mrgreen:

[DesmoBM]

Just want to say thanx for all the help. It was very nicely explained. I need to get this done tomorrow as this is my commuter bike around campus (and a massive one that it is... Texas A&M, takes me 15 minutes to get from one side to the other)

On another note, I'll be moving to Chicago pretty soon and was wondering if you guys recommend any particular motorcycle shipping companies. I heard of one that is quite cheap, around $300 or so and they do crate shipping through air frieght. I dont recall the name (something like Federal Transport), if someone does, please let me know.

Once again, thanx.

[MarkusN]

You can get away without removing the tank if you thread a lenght of strong string/wire in when pulling out the old cable, then use that to pull in the new one. Got that hint from the Clymer manual (I think), and it worked well for me.

[DesmoBM]

Just as a follow-up:

I dont have too many tools on me, Im quite transient at this stage, so I went to the local Suzuki shop and they didnt have the wire in stock, so I said to go ahead and overnight it from Suzuki in Houston. Well, the Houston shop messed up the order and since it was delayed by one day, I got the part and shipping for free  

The local shop only charge me for half an hours worth of labor. Not bad I say. And it feels good now. Thanx for all your comments.