So, my clutch cable snapped just a few days out from a parade I'm scheduled to ride in. Verslagen came through in a pinch and overnighted me the part for dirt cheap, plus a lot of shipping
So, if you need to know how to do this, it's pretty simple. Forgive my poor terminology- and this may not make sense just reading it, but if you get the parts, it's a breeze! (And I have almost no mechanical experience).
1. Remove the seat- two bolts under the back outside edges where it mounts to the frame.
2. Drain the fuel tank: either siphon it, or just disconnect the vac tube from the petcock and let it drain into a fuel can.
3. Disconnect the petcock from the fuel tank- two bolts under the edge of the tank.
4. Disconnect the speedometer cable (spring-wrapped cable on the right side that runs down to just above the clutch- just unscrew it- but don't lose the gasket inside.
5. Remove the tank- two bolts under the front of the seat, straighten the handlebars, and slide the tank forward and up, then disconnect the electrical junction- just pull it apart.
6. Unscrew the clutch cable at the handlebars- just use a pliers and turn it so the openings line up, and pull the cable out of the lever.
7. At the clutch arm, use a flat-tip screwdriver and gently pry open the part that holds the end of the cable in. Then in the threaded guide, just above it, just unscrew it and slide it out of the notch.
8. Loosen the zip-ties (you shouldn't have to cut them!) and slide the whole assembly out.
Now to replace it.
1. Run the new assembly through the zip ties.
2. Reattach the end at the lever and then turn the threaded guide until the openings don't line up so it holds the cable in place.
3. Reattach the end at the clutch arm- replace the threaded guide in the notch and then the cable goes into the arm. Gently bend the piece back in to hold the cable.
4. Replace the tank- two bolts.
5. Replace the petcock- two bolts (just insert the weird yellow "tape" thing back into the slot). Reattach the vac line.
6. Replace the seat- two bolts.
7. Refill tank, and fire it up.
8. Adjust the threaded guides at the lever and clutch arm as needed for tension, etc.
I may be missing something- my manuals are on my other computer, so I just did it by the seat of my pants, but it seems to work just fine.
Only question is: WHAT ARE THESE?????
(I didn't remove them, but they were on the floor when i was finished, and they weren't there when I started)
They're about as big around as a quarter, and the "washer" seems to be magnetized...
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