Clutchless in Texas

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HOTT
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Clutchless in Texas

Post #1 by HOTT » Mon Jul 26, 2010 2:35 pm

This past Saturday night I was preparing to take the trusty Wing for a cruize-a-round. I pull in the clutch lever, snick her into gear and start heading out the drive way--Uhh... the clutch lever is still pulled tight ! Hit the red switch. WT%$. It seams my brand new clutch cable broke at the LEVER (and I even sprang for the expensive one). Well I know my local guy would make good on it but they're closed until Tues. But I have got to show off this baby tomorrow at somebodys local Sunday get together. The following is how I think my hero Rube Goldberg might have saved the day.
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As you can see someone was asleep at the swedging machine. Cable pulled out of the lever lug (actually amazed it worked as long as it did)
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The Plan; Using some brass stock, repair cable without removing from bike and hopefully be riding before Tuesday. lolol
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First thu drill 1/8'' hole in a piece of 1/4'' solid brass (I went about 3/8'' from end I'll trim to fit later). Follow up with a 5/32'' recess just enough to get bulge caused by factory cut to fit in (see plan). Lastly use a cut off wheel to lay a slot to cable pass thru.
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Before slipping the brass core over the cable I sweated some rosin core solder on to the cable end (rosin core will not attack the steel cable over time). This will allow less heat to be used on the next step.
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Using some #132 brass tube (9/32x.014) sleeve BOTH sides of the cable end core. Sweat solder the whole thing use cutoff wheel to remove excess and tidy up with a file.
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The job took less than 45min. and the brass can be bought at Ace or hobby shops cheap. I'm probably the only person this ever happened to(I confess I did not do a search), but thought it would make fun reading. crossy.gif Ric
If we can't fix it, we can fix it so no one else can.


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greatrespectforbeer
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Re: Clutchless in Texas

Post #2 by greatrespectforbeer » Mon Jul 26, 2010 2:39 pm

Awesome. Mind if I borrow that trick next time my cable breaks????
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Papa Bear
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Re: Clutchless in Texas

Post #3 by Papa Bear » Mon Jul 26, 2010 2:44 pm

Neat fix. You can also get ball end repair kits from a good bike shop or on-line. If your cable broke so easily, I'd venture to guess it wasn't routed correctly. Seen it many times. They bind and the cable snaps right at the ball. Could have been a crap cable to begin with, but I'd make sure of the routing with the new one. I'm sure someone here has a picture of the correct routing they can post.
Papa Bear

Keep your head on a swivel and your eyes open!

Current bikes: '78 Wing with '76 false tank, '76 Wing (GLzilla) with 1200 bottom and 1000 top end, '82 GS850 beater bike. '84 1200 project motor.

Previous bikes: '72 Yamaha 250, '76 Kawi KZ400, '62 Triumph 650 Bonnie, '74 Triumph (Chopped), '78 Kawi 750 Twin, and '76 GL.


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