SuzukiSavage.com - Repairing engine clutch cable adjuster

catfishunter99

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Repairing engine clutch cable adjuster
05/31/17 at 18:56:36

So the PO owner of my bike took it upon themselves to break half of the female threaded hole where the clutch cable threads into the engine clean off. I don't have an exact picture of my bike handy right now but the piece in question is below the two nuts (#5) shown below from the owners manual. What I am left with is half of the threaded hole and all that is holding the cable housing from sliding out are zip ties. Anyone have experience with a fix that may work for this?

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catfishunter99 YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 42 WI Gender:	Re: Repairing engine clutch cable adjuster Reply #1 - 05/31/17 at 18:57:53 Here's the picture
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Repairing engine clutch cable adjuster Reply #2 - 05/31/17 at 19:41:11 The hole is not threaded... it's just a thru hole.
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batman

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Re: Repairing engine clutch cable adjuster
Reply #3 - 05/31/17 at 20:24:23

Well if it were me.......I'd try to measure the gap under the speedometer nut and use a piece of flat bar to form a plate to fit the top of the boss ,with one hole for the clutch cable and the second to fit over the threaded part the speedo cable screws to ,even if it meant grinding /filing the speedo end to fit under the nut it should be strong enough.You have to take care to make sure the nut tightens down far enough to compress the O-ring seal on the speedo cable to avoid an oil leak and holds the end of the plate down. Once you have it formed right ,you could heat it with a torch and oil clench it to harden giving it more strength. All the force is downward when you squeeze in the clutch handle ,there is no force on the plate upward ,that's why no nuts are shown underneath in the picture. this fix should work,or it's time you made friends with a good welder....just had another thought if you need the nut on the speedo cable to stand off the base you might use athin washer sandwiched in between two O-rings under the speedo cable nut,or get longer bolts for the starter motor and make an L shaped bracket to reach around to the clutch cable.

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« Last Edit: 06/01/17 at 14:56:29 by batman »

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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: Repairing engine clutch cable adjuster Reply #4 - 06/01/17 at 04:14:33 Build it up with some JB. File the surface back to flat, redrill the hole.
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stewmills

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Re: Repairing engine clutch cable adjuster
Reply #5 - 06/01/17 at 06:47:26

Is it possible to get a small hose clamp around that piece (what is left of it)? In a pinch that may help stop it from bouncing out, but not sure if I would trust that to not vibrate off eventually.

I can't tell from this photo (bike is at home) but it looks like you can get all the way around with a clamp?

JB weld is a good tool as well, just have to make sure you degrease things so you get a good bond.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Repairing engine clutch cable adjuster Reply #6 - 06/01/17 at 06:48:33 Metal chips/ flakes in an epoxy make it stronger. Build a "form " with plastic and tape, use JB Weld, and follow the recommendation above. A machine shop that has worked aluminium can give you some filler material. There's no instruction manual for such a repair. It's a Skills test. I hope you win this..
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catfishunter99

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Re: Repairing engine clutch cable adjuster
Reply #7 - 06/03/17 at 16:59:46

batman wrote on 05/31/17 at 20:24:23:

Well if it were me.......I'd try to measure the gap under the speedometer nut and use a piece of flat bar to form a plate to fit the top of the boss ,with one hole for the clutch cable and the second to fit over the threaded part the speedo cable screws to ,even if it meant grinding /filing the speedo end to fit under the nut it should be strong enough.You have to take care to make sure the nut tightens down far enough to compress the O-ring seal on the speedo cable to avoid an oil leak and holds the end of the plate down. Once you have it formed right ,you could heat it with a torch and oil clench it to harden giving it more strength. All the force is downward when you squeeze in the clutch handle ,there is no force on the plate upward ,that's why no nuts are shown underneath in the picture. this fix should work,or it's time you made friends with a good welder....just had another thought if you need the nut on the speedo cable to stand off the base you might use athin washer sandwiched in between two O-rings under the speedo cable nut,or get longer bolts for the starter motor and make an L shaped bracket to reach around to the clutch cable.

Batman, Thanks for the great idea! I was able to make a plate like the one you described out of 1/8" aluminum. Drilled a 5/8" hole for the speedo and a 5/16" hole for the cable painted it black added 1 o ring between the plate and the speedo nut to secure the plate. Problem solved!!! No more having to reply on zip ties. I am one happy biker😀. Thanks again for the advice!

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batman Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 3806 osceola new york Gender:	Re: Repairing engine clutch cable adjuster Reply #8 - 06/03/17 at 21:41:57 Just thinking outside the box,glad it worked!
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