I was on such a roll today and was able to get my clutch basket on the bike, safety wired the three engine shock absorber bolts and mounted the engine sprocket. I then was able to put a new primary chain on and adjust its tension.
I then attached my clutch cable and had to really depress the clutch rod to attach the rod to the cable. I am out of distance adjustment on the clutch cable and my clutch will not disengage (the clutch still spins freely with the clutch cable fully extended.
I measured my cable COVER length and it is 53 1/8" long. According to the technical section the cable cover should be 52 3/8" long. It appears my clutch cover is 3/4" too long. I imagine if I shorten the cover 3/4" my clutch should disengage when the clutch hand control is not depressed. The overall length of my clutch cable is 58" and I couldn't find the correct overall length of the cable in the technical data.
If I need to shorten the clutch cable cover, how can I do this. I have never done this so I am not sure how to proceed. Any help is greatly appreciated.
If I have to order a new cable, I am looking at a long wait as I am in the USA and most of my parts are coming from England.
I very carefully used my Dremel to cut the cable cover to the proper length. I then, even more carefully, cut each individual metal wrapping strand on two sides to remove each from the cable. Not bad for a novice!! I didn't want to have to cut the tip of the cable off and then have to solder it back on.
Should have some pictures up soon of all the progress on the bike. I can see some light at the end of the tunnel thanks to all the help I have received from here and from Kevin in LA!!
I have done this several times to increase the free length of a cable. After you cut away the plastic sheath, Carefully with some side-cutter pliers you can unwind the outer cable which is like a tough spring. Once you get hold of it and start unwinding it becomes easier. Just snip off at the desired length and file the burr.
You need to adjust the cable according to the manual You should have some free play with the clutch engaged. When disengaged by the handlebar lever, the clutch actuating rod on the gearbox should be vertical and not leaning in or out.
The straightest run of a light oiled cable will give you the lightest action. Ron
