Clutch Cable Length

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Niagara850

Niagara850

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Jul 7, 2010
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How many are using the 51 inch (UK bar) clutch cables on US bars? I had a 56" but it looped up way too high in front of the clocks. Had a friend shorten it to 51 1/2" but lever end keeps popping off after 200 - 300 miles. Tried both bird caged button and bullet end fit that fits into a button. Andover and Old Brits lists 51" for both US and UK bars. Venhill and Walridge 56". I guess as long as it reaches its okay or does the loop provide some cushioning effect for longevity?
 
I've found that you can't reliably solder a new end on the cable with a soldering iron. I now use a torch, a silver solder alloy, and a special flux for stainless steel. In the past I've soldered with an iron and those repairs always popped off eventually. I hear the solder pots work well too, but I've never used one.

I have ridden home 3 times in the last 40 years with a broken clutch cable. You "check up" on the throttle as you shift the gear lever. It's not that hard to do smoothly, but certainly it's scarey the first time you do it. It's certainly not good for the gearbox. It's probably impossible to do in a city with traffic lights.

I bought a "bolt on" set screw cable end from flanders that I carry in my jacket pocket just in case of the lever end popping off. It was relatively cheap and it's a good thing to have in an emergency. I also carry an extra clutch cable (an old non-teflon lined one) tucked away in the fairing in case powershifting or the "bolt on" repair isn't an option. My bars are low and 29" wide, and my cable is 51.5" overall length with 3" of that cable length exposed outside the sheath. I think that cable length will work for slightly wider bars too because I do have some "loopyness" in the cable, but it's not a very excessive amount.

Here's the link to their set screw cable end page. Might be a good tool box dweller.

http://www.flanderscables.com/actio...ator=Contains&Type=Fitting&Catagory=CablePart
 
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Venhill will make them any length you want at no extra charge, it just takes a few extra days.

B
 
Traffic lights got me ... and I had a canal to cross. I'll pick up one of those bolt on cable ends. I tried to silver solder the bullet end back on. Used a torch and the special flux but it pulled right off. I had never lubed it as it had a plastic liner , cleaned with acetone and heated the flux on first. Faulty technique or contamination on the cable perhaps. I'll look into the Venhill custom order.
 
Had a clutch cable go on my MK3 and it wasn't easy to start, as soon-as it fired up in gear the sprag would disengage. But eventually got it going ok with good clutch less gear changes and 20 miles from home. Never had to stop ( thank god ). Many years driving trucks with crash boxes served me well.

ELLIS
 
Coming home from work many years ago had the clutch cable break , as mentioned above just speed shifted my way home finding neutral was impossible so had to ignore a couple stop signs .... lucky traffic was mostly nonexistent .... always meant to ride with spare cable but never have got around to it .... keep an eye on cable around lever and it still like new .... figure if I carried a spare I would prolly need it .....
 
If you are going to order a cable, get 2. I put the spare cable routed under the tank and laid along side the operated cable and secure it with zip ties. That way when and if it breaks again you won't have to remove the tank in the field to replace it.
 
Well after a pleasant trip trip to the Dalmation Islands and Zagreb I ordered up a 52" Doherty heavy duty cable thru Walridge. Fits nicely. The cylinder at the lever rotates easily. It has a nylon? wrap same as the sheath lining around it. The 56" spec must be for Hi Rider bars although it's described as US bars in various listings. AN has it right. When I had the cable cut down it ended up at 51 1/2". The lever end cylinder used was a snug fit it but appeared to move with the lever but may have been binding under pressure. Time will tell. I'll stay within the 175 km CAA Bike Rescue radius for a few hundred miles before venturing further afield ;).
 
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