removal of clutch cable

radiofun · Jun 5, 2011

Hi Everyone,

How do you remove the ball from the end of the clutch cable? I thought it was soldered on but heating it up didn't loosen it.

pete.v · Jun 5, 2011

It's molded to the cable end. You remove that ball. you ruin the cable.
Remove the lever at the handlebars and unattach the cable at that end. The cable can now be removed from the actuator arm. in addition, backing out the clutch adjusting screw on the primary side will offer more relief.

radiofun · Jun 5, 2011

I'm replacing the original levers with Brembro levels and those use a smaller barrel (i.e., the part that fits into the lever). So, the problem is that the original barrel is too large for the lever.

Rich_j · Jun 5, 2011

Both ends are usually brass soldered on for high load applications like clutch and brake, solid solder ends are usually on throttle cables.
The cable after it's passed through the nipple is splayed out or deformed some other way so it forms a mechanical plug which is pulled into the body of the nipple, the plug becomes solid when its soldered. Your problem may be that you're trying to pull the nipple off which is the wrong approach.
Heat the nipple till the solder melts and push it up the cable, then you can cut the old cable end off and start again with a new nipple.

radiofun · Jun 5, 2011

thanks you guys.

Holmeslice · Jun 5, 2011

radiofun said:
I'm replacing the original levers with Brembro levels and those use a smaller barrel (i.e., the part that fits into the lever). So, the problem is that the original barrel is too large for the lever.

Just drill out the Brembo to fit. I do it all the time.

debby · Jun 6, 2011

The other problem with cutting the cable and putting a new end on is that the wire will be too short with respect to the housing and you may find the clutch is dragging because you're not getting enough cable pull (ask me how I know). Also, any time you need to replace the cable you'll have to do the cutting and resoldering again.

Far better to just drill out the lever and use a standard cable as Kenny suggests. That's what I ended up doing.

Debby

radiofun · Jun 6, 2011

Drilled it out and all is well. Simple is better. Thanks

daveparry · Jun 7, 2011

the wire will be too short with respect to the housing and you may find the clutch is dragging because you're not getting enough cable pull
-------------------------------------
If the wire is too short the clutch will slip, not drag!

Dave.

Rich_j · Jun 7, 2011

debby said:
The other problem with cutting the cable and putting a new end on is that the wire will be too short with respect to the housing and you may find the clutch is dragging because you're not getting enough cable pull (ask me how I know). Also, any time you need to replace the cable you'll have to do the cutting and resoldering again.

Far better to just drill out the lever and use a standard cable as Kenny suggests. That's what I ended up doing.

Debby

I agree with the drill out the lever being the best option but if you still want to modify the cable you just take the same amount off the outer you lost from the inner.

Ron L · Jun 7, 2011

The best reason for drilling out the lever is that the cable is wear/maintenance item. Meaning that down the road it will wear out or worse yet, break. Much easier to just get another Norton cable than having to make another. Especially if you are on a road trip!

removal of clutch cable

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