Clutch cable replacement - Kawasaki Versys Forum
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post #1 of 10 (permalink) Old 07-17-2016, 11:16 AM Thread Starter
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Clutch cable replacement

How hard is it to replace the clutch cable? Found out mine broke today at the lever end just about half the strands holding it left.

Thanks

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post #2 of 10 (permalink) Old 07-17-2016, 11:49 AM
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This thread has good info on the clutch cable.
http://www.kawasakiversys.com/forums...e-fraying.html

Keeping the cable itself lubed is regular maintenance. The issue is keeping the ferrule end lubed and recess it rides (rotates) in at the clutch lever. Re-routing helps also as it unbinds the cable some. I don't know if this is an issue on later models. If you look under the lever and just operate the clutch (with it dry) you can see the cable actually bend a little at the joint before starting to rotate in the keeper. That slight bending multiplied by many clutch cycles is the killer. Also, it's not hard to change if you are mechanically inclined or as the young people say, you've got skills. Good Luck Man!

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Last edited by BayouVersys; 07-17-2016 at 11:52 AM.
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post #3 of 10 (permalink) Old 07-17-2016, 12:46 PM Thread Starter
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Read through a few posts and the manual. Still have a question. Do you need to remove the two bolts and clamp at the clutch /engine end to remove or replace the cable?

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post #4 of 10 (permalink) Old 07-17-2016, 04:46 PM
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Clutch cable replacement

Quote:
Originally Posted by Crash View Post
Read through a few posts and the manual. Still have a question. Do you need to remove the two bolts and clamp at the clutch /engine end to remove or replace the cable?

Crash
Yes


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post #5 of 10 (permalink) Old 07-17-2016, 05:10 PM
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I changed mine with no tool in the parking lot at work, after it broke, in 15 min.

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post #6 of 10 (permalink) Old 07-17-2016, 05:22 PM Thread Starter
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Quote:
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I changed mine with no tool in the parking lot at work, after it broke, in 15 min.
Not sure this is helpful.

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post #7 of 10 (permalink) Old 07-18-2016, 09:13 AM
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Not sure this is helpful.
I'm sorry, you asked: How hard is it to replace the clutch cable?

And I said is not hard at all...
I did it once, in my parking lot with no tools, 2 years back.
I don't remember all the steps, but I'm sure you can do it.
You remove the cable from the handle bar, and the you push it and remove it from the clutch.

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post #8 of 10 (permalink) Old 07-18-2016, 12:01 PM Thread Starter
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How did you remove the two bolts holding the clamp without any tools, or does it not have to be removed for this change?

Only way I can see getting at the bolts is with a ratchet and extension bar. Since the previous post stated they did need to be removed, I am trying to see which is correct or possibly if both are and how that could be.


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post #9 of 10 (permalink) Old 07-18-2016, 05:52 PM
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There is a very good procedure in the service manual. For the 2015 model it is in the clutch section 6-6. One trick is to tape the new cable to the old cable and use it to pull the new cable through - that way you will have it routed exactly like the original cable (extremely important!) and you will not have to remove any bodywork. It does really speed up the job.
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post #10 of 10 (permalink) Old 07-19-2016, 12:05 AM
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clutch cable replacement

while replacing the clutch cable tends to be one of the easier tasks to accomplish on your Versys 650
BUT BEFORE YOU ACTUALLY DO IT
you gotta determine just why half of those cables have broken in the first place
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