Clutch cable replacement - is there a trick here? - Kawasaki Versys Forum
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post #1 of 11 (permalink) Old 04-14-2018, 12:57 PM Thread Starter
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Clutch cable replacement - is there a trick here?

Hello,

I suck at these kinds of things, so I am probably just doing something really stupid, but I am trying to replace my clutch cable. The very end of the cable on the engine side won't slip out of its little slot. Is there a trick to this?

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post #2 of 11 (permalink) Old 04-14-2018, 01:23 PM
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Loosen the boot off the cable, slide it back, then move the cable forward enough to slip the actual cable line between the gap in the bracket(this can only be done if there is enough slack in the line to begin with). Once the cable is removed from the bracket, you will have plenty of slack to remove it from the clutch. Installation is reverse order.
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post #3 of 11 (permalink) Old 04-14-2018, 04:23 PM Thread Starter
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Quote:
Originally Posted by Rebel13 View Post
Loosen the boot off the cable, slide it back, then move the cable forward enough to slip the actual cable line between the gap in the bracket(this can only be done if there is enough slack in the line to begin with). Once the cable is removed from the bracket, you will have plenty of slack to remove it from the clutch. Installation is reverse order.
Thanks, I got it done with great assistance from a fellow rider locally. We did have some trouble getting the cable right at both ends until we took off the handlebar section. The part seems to be the exact length you need and if you don't do that, it just won't go.

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post #4 of 11 (permalink) Old 04-15-2018, 07:53 AM
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Aside from creating some slack from the upper adjustment bolt, you have to change the 5-position clutch lever depth adjustment to clear the hole.
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post #5 of 11 (permalink) Old 04-25-2018, 11:14 PM
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If you have to replace the clutch cable, do yourself a favor and buy two. Route them both where the old cable was, connect one and zip tie the ends of the spare. I cover the end of the unused one with shrink tube to keep out contamination. If a clutch cable is going to break, you know it will be when you are in some god forsaken location, with maybe no buddies around. This way, you can be on your way in about 10 minutes.
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post #6 of 11 (permalink) Old 04-26-2018, 12:00 AM
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If you have to replace the clutch cable, do yourself a favor and buy two. Route them both where the old cable was, connect one and zip tie the ends of the spare. I cover the end of the unused one with shrink tube to keep out contamination. If a clutch cable is going to break, you know it will be when you are in some god forsaken location, with maybe no buddies around. This way, you can be on your way in about 10 minutes.
That's a great idea.... if you choose to not inspect and lube every year...

I suspect it's really tight to pass a 2nd cable. I find the clutch cable easy to lube and inspect, and the throttle cable to be thin, hard to lube and hard to inspect (due to spring and tension) and throttle cable fails first, at the bottom end where it rubs on the edge of the metal sleeve (nice design, kawa!).

I carry a cable repair kit (just the thin and thick wires and tips, no sleeves); it's small like a cd or old 3.5" floppy.
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post #7 of 11 (permalink) Old 04-27-2018, 12:01 AM
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It took a little work to get the transmission side of the clutch cable attached, but it wasn't that difficult. For the throttle cable I take the upper side apart and thoroughly lube it, using a liquid graphite based lube, and use the needle attachment for the graphite lube to sneak it into the sleeve to make sure the area where it rubs the sleeve is thoroughly lubed.

Clutch cable is the easy one, and will fail around 6k miles if never lubed (previous owners of my bike never lubed the clutch cable and mine broke at 6.5k). I've more than doubled the mileage that the original cable made it with no signs of wear, and I probably ride the bike a lot harder than the previous owners (bike was set full soft when I got it and the original rear tire had almost 2 inch chicken strips).
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post #8 of 11 (permalink) Old 04-27-2018, 07:09 AM
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...
Clutch cable is the easy one, and will fail around 6k miles if never lubed (previous owners of my bike never lubed the clutch cable and mine broke at 6.5k). I've more than doubled the mileage that the original cable made it with no signs of wear.
...
What?! I had only 1 failure, on the throttle cable which I never lubed, it was at 90'000km... There was a defect for sure, or cable sleeve misaligned or something...
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post #9 of 11 (permalink) Old 04-27-2018, 02:26 PM
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Quote:
Originally Posted by mrvwbug View Post
...Clutch cable is the easy one, and will fail around 6k miles if never lubed (previous owners of my bike never lubed the clutch cable and mine broke at 6.5k)....
On my '08 the clutch-cable, NEVER lubed till around 40,000 miles when I noticed a few strands were broken, finally broke at around 52,000 and was replaced.

NOW I lube them fairly regularly.

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post #10 of 11 (permalink) Old 05-10-2018, 07:04 PM
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When I googled the clutch cable issue I saw quite a few other reports of them failing from neglect at 6k ish miles. My throttle cable which also was probably never lubed by the previous owners shows no signs of premature wear, it was definitely on the stiff side before I lubed it, but it is back to being as smooth as a new throttle now.
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post #11 of 11 (permalink) Old 05-12-2018, 04:20 PM
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To me, 6,000 miles to failure sounds a BIT early....

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