Cable doesn't fit into trans.

The Buckeye Rider · Oct 19, 2017

My new VenHill clutch cable outer sheath won't slide into the hole on the transmission.
The hole diameter is 5.4 mm.
The swedged cable end that should slide into the transmission hole is 6.4 mm
The old cable & my spare measure 4.8 mm.
Am I missing something here? I'm definitely not new at this but at this point I'm a little bit past frustrated.

My physics teacher told me the only way to fit 6.4 into 5.4 is by using a big hammer but it's at an odd spot and I can't get a good swing at it.
Ride On (maybe)
Dave

1975 Norton Commando MKIII Roadster

madass140 · Oct 19, 2017

you obviously have the wrong cable

acadian · Oct 19, 2017

I've had similar issues, small file to the nipple solved it

gortnipper · Oct 19, 2017

acadian said:
I've had similar issues, small file to the nipple solved it

I had the same problem with the pear nipple and filing it down is fine.

concours · Oct 20, 2017

My first Venhill clutch cable didn't fit the adjuster on the perch. Sent back.

Second one was too long for the US bars. Lived with it.

Edit: SECOND one fit perfect, lasted 25,000 miles. THIRD one was too long, lived with it.

850commando · Oct 20, 2017

is the length correct, then you should be ok. mine was also a tight fit through the hole , but because it is pear shaped, you can either file it as suggested,or just force it through.

NortonMKIIA850 · Oct 20, 2017

Interesting – I recently fitted a Venhill clutch cable that I bought as a spare around 13 years ago – it fitted perfectly in all respects, if you discount needing to push the nipple through the hole in the gearbox as it was a tight fit. Maybe their parameters have drifted since I bought mine? If so they need to know ...

850commando · Oct 20, 2017

mk2a850, your description is about how tight mine was...

NortonMKIIA850 · Oct 20, 2017

Yes indeed, the OP's problem is a more serious concern. Unless as madass140 says it's just the wrong cable ...

gortnipper · Oct 20, 2017

Wrong cable. The neck on mine is 5.06mm and it fits like a glove.

850commando · Oct 21, 2017

i need to correct my comment, (just realized the OP's dimension info) i would contact the supplier to confirm if indeed a wrong cable was in the package, and return it if possible

how has this resolve Buckeye?

The Buckeye Rider · Oct 21, 2017

850commando said:
i need to correct my comment, (just realized the OP's dimension info) i would contact the supplier to confirm if indeed a wrong cable was in the package, and return it if possible

how has this resolve Buckeye?

Supplier confirmed the VenHill cable end is too big but it is the correct cable(?) suggested I Dremel the end, enlarge the whole in my transmission case(never!) or send it back for a Barnett cable that would fit.
I resolved it by finding another supplier.
Ride On
Dave

Cable doesn't fit into trans.

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