Aargh new clutch cable nightmare!

[BeerEnthusiast]

After my clutch cable snapped on the way to work, I’ve gone and sorted a new one. AFAIK it’s the correct part (R1100GS ‘95, part no: 32732 324 961)

Removed old cable, routed new cable through bike, new tie wraps etc...
fitted it into, and greased, the nipple holder (giggle) at lever end, fine...

Went to hook it into the clutch arm... cable appears too short! Balls!

I’m assuming I have to adjust the clutch arm now - is this the case? And how the rook do I get at it without removing half the bike!

Help me (please)

 

[JJH]

Clutch arm before lever? JJH

 

[davegs]

Don't fit tie wraps till it's all working ok.

 

[dean0n0]

Take the pivot bolt out of the lever, remove the lever from the perch, see if that gives enough slack.

 

[casper]

Make sure you have free play at the clutch arm once new cable fitted.
Play at the lever doesn't necessarily mean you have free play at the arm.

 

[BeerEnthusiast]

With the cable fully extended (ie, lever fully out), it wont reach the arm. If I pull the arm towards cable (ie, towards front of bike, disengaging clutch), the cable is still about 5mm from the arm. Deffo need to move the arm forward by adjusting. Off to Halfrauds to get a 13mm deep socket!

Once sorted, Ill set the lever adjustment screw to 12mm gap etc and adjust play from the arm.

Getting to that adjuster seems like a pain in the arse!

 

[dean0n0]

Take the lever out, (remove the pivot bolt) connect the arm end then put the lever back in.

 

[Steptoe]

Take the lever out, (remove the pivot bolt) connect the arm end then put the lever back in.

It'll still need adjusting as the new cable hasn't stretched like the old cable

 

[Posh Pete]

Did you compare length with the old one?

 

[dean0n0]

It'll still need adjusting as the new cable hasn't stretched like the old cable

Sorry, thought that went without saying...

 

[GotFog]

I think it is a 13 mm headed jam nut. Dont quote me on that. The bolt that resides inside and is the adjuster I think is a 10mmbolt. I use a 1/4 inch ratchet with a good long extention bar. I am not at home but i say it is at least 12 inches long maybe 15. Then a pivot socket then the 13 mm socket.
Turn socket counter clockwise to loosen jam nut assembly. The actual length adjuster is the bolt and should now turn freely. Once cable is on turn bolt head till you get the freeplay at the clutch handle desired. I think it is about 5 to 7mm gap?
Once that is set compress clutch lever fully and hold with clamp. Now you can tighten jam nut without upsetting bolt adjustment. One man operation and no special tools.

Chris Harris technique.

 

[BeerEnthusiast]

Is all done! 13mm long, UJ, and extension.
Originally there was about 2inches of movement at the arm that I thought was disengaging the clutch... turns out that was just free play! Now all properly adjusted at both ends. Sorted. Cheers for all the pointers!

 

[Steptoe]

Sorry, thought that went without saying...

Then what's the point or benefit of your previous advice below ?

Take the lever out, (remove the pivot bolt) connect the arm end then put the lever back in.

 

[dean0n0]

It's the easiest way I've found to do clutch cables.