Replacing clutch cable...

Can anyone offer any tips on this? E.g., does the outer gearbox cover have to come off to R&R the old cable where it fits into the "fork" attachment? My Haynes manual suggests the cover doesn't have to come off, but I'm having a devil of a time... thanks all - BrianK

It should not be necessary to remove the outer cover to disconnect the clutch cable (although I guess it can depend on the shape of the cable nipple?) but it can be a bit awkward to do.

First ensure that the clutch cable is completely disconnected from the handlebar lever so that you have lots of slack on the inner cable, it should then be possible to pull the nipple down until it clears the fork, then hold the nipple with some needle nosed pliers, a slight twist and a pull should free it, the fork may need to be held up with a finger or a small screwdriver to give enough clearance as you do this, and do the reverse to refit it.
If that does not do it then slacken off the clutch centre adjuster nut and then unscrew the adjuster a few turns (after first screwing it in to check the adjuster setting) but don't remove the adjuster completely as the lifter arm (that the cable connects to) can drop out of position.



A worthwhile modification is to grind a small amount of metal from the fork ends if you do take the outer cover off, as that makes the job of removing/replacing the cable a lot easier the next time you need to do it.

Many thanks, I'll give it a shot - BrianK

brian, when mine broke it was easy to get it out of the "fork" end. i re-routed the new one and found it impossible to get it onto the handle bar lever. i unscrewed the slotted round head that holds the lever on, threaded in the cable, and pivoted the handle back in place and re-attached. hope you got her done by now, but just in case you did not, that worked for me. cheers

watching this link, I ask myself why it was so easy to replace mine....
I had the gearbox inner and outer cover off a few weeks ago and of course the clutch cable was removed for access........
all I did was fully loosen the adjuster at the clutch lever, slide the cable and housing out of the fixed part on the handle bar and then push the lead nipple out of the lever. At that point, the lead nipple on the clutch operating arm inside of the outer cover simply slipped down out of the forked end. the whole cable pulls out of the gearbox cover...
there should be almost no tension on the cable when the adjuster is fully loosened.
good luck.
Commando74

Commando74 said:

watching this link, I ask myself why it was so easy to replace mine....
I had the gearbox inner and outer cover off a few weeks ago and of course the clutch cable was removed for access........
all I did was fully loosen the adjuster at the clutch lever, slide the cable and housing out of the fixed part on the handle bar and then push the lead nipple out of the lever. At that point, the lead nipple on the clutch operating arm inside of the outer cover simply slipped down out of the forked end. the whole cable pulls out of the gearbox cover...
there should be almost no tension on the cable when the adjuster is fully loosened.
good luck.
Commando74

Click to expand...

That's what I do with mine, the cable disconnects very easy from inside the gearbox.

Thanks all. Completely coincidentally, my wife broke the clutch lever on her Triumph yesterday. Since we are to ride today, I decided to take the one off the Norton and see if she could use that one while we wait for a chance to buy her a new one. Only way to get hers off was to remove the pivot pin, at which point the light bulb appeared over my head.

Appreciate all the responses. I'm new to the Board (just bought a 73 850 Commando off of eBay and will surely have a few million questions as I proceed with my rolling restoration...so please bear with me!)

- BrianK

Worked like a charm. Thanks all - BrianK