Clutch cable replacement

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Ken L.
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Clutch cable replacement

#1

Post by Ken L. »

Are there any good posts on replacement of the clutch cable with the engine in the bike?
78 GL1000

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Ken L.
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ericheath
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Re: Clutch cable replacement

#2

Post by ericheath »

Tape old cable to new cable when you pull it out. I think I taped the top of the new cable to the bottom of the old cable.
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Re: Clutch cable replacement

#3

Post by Whiskerfish »

Not that I am aware of, but proper routing is important. The cable should enter the small opening just forward of the choke knob and pass in front of the headstock through the Right hand triangular frame opening, then along the inside edge of the right hand frame tube. There should be a cable suspender about mid way back. The worst spot is snaking it through between the frame and the fuel tank. I often take the brake switch wires apart and remove them so as to not tug and pull on them excessively. No sharp turns on the cable.
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Placerville
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Re: Clutch cable replacement

#4

Post by Placerville »

Although you might cringe at the following suggestion, it's actually easy to do. When replacing throttle and clutch cables, I find it very 'freeing' to remove the top shelter. When removed, you'll find you have TONS of access to previously inaccessible areas and your cable replacement will be a breeze.

1. Pull the pins on the left and right side false tank covers and remove them. (Leave the top shelter lid in place.)
2. Disconnect the connector for the fuel gauge to the harness.
3. Remove the four bolts holding the shelter to the frame.
4. Remove the air box.
5. Disconnect all of the harness connectors on the left side of the shelter.
6. Lift off the shelter and be amazed at how much access you now have to your cables.
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RogueCreature
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Re: Clutch cable replacement

#5

Post by RogueCreature »

Yep...that seems to be the proper case...i did this when i replaced push pull cables...clutch snapped the other day, I guess Its time to take the top housing off again. might do speedo and tach while im at it as well. last time i disassembled too much of the false tank lid/gas guage. i remember thinking i should just pulled the connector off but i didnt see it at the time, hopefully i can see it this time.
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Re: Clutch cable replacement

#6

Post by OhioBill »

Look up Puffy page and how he routed his clutch cable. It seemed to make sense. It is not the stock routing. The most difficult part of your, I suppose, is the attachment at the motor. If you have a lift table it is not too bad. Still requires a lot of swearing as you work in the close quarters under the frame.
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Re: Clutch cable replacement

#7

Post by scootsx2 »

Its easy to replace the clutch cable with the engine in the bike. As mentioned in earlier posts, just be careful of the cable routing.
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jdvorchak
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Re: Clutch cable replacement

#8

Post by jdvorchak »

Personal preference tip here. I lube even new cables before I install them. Make sure the ferrule at the clutch lever is lubricated with high temp grease and confirm that it doesn't bind moving through the clutch lever. Clean and lube all moving surfaces of the clutch lever and pivot pin again with a very thin coat of high temp lithium grease.

I use High Temp grease not because it gets hot up there, but so it doesn't melt in the sun and start dripping.
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