Finishing up my apes, I need to install the clutch cable. I've heard that doing the ball/ramp end first before re-assembling the clutch lever on the grip is the easier way to go. This is what I've done. However, no matter how much I fiddle with the [freeplay] adjuster, I cannot get enough slack to get the lever and cable assembly into the switch housing. I need like 1/4 inch more.

Does the ball/ramp assembly need to be in a certain position to get enough slack? It wants to sit in a position that allows maximum cable length in the side cover. I don't know if I can make it set otherwise. I'm not sure if creating slack with a clutch adjustment will work since my cable isn't installed at this point.

Any tips???

 

Dis-adjust the clutch at the hub, that will give you the slack that you need......

11/16 box wrench and a 7/32 allen, completely unload the adjuster screw.....

 

So I'll be loosening the hub, assembling the lever and then doing a clutch adjustment from there to take out the slack? Don't want to mess this up since I'm not sure dis-adjusting is in the manual. [&:]

Whiff

 

1) Loosen cable all the way by shortening adjuster. Make sure actual cable is pushed into the cable housing at the transmission. You need the ball and ramp assy set in released position.

2) Perform adjustment (on cold primary) at derby cover. Loosen center allen, lightly snug, back out 3/4 turn. If step one is not done and ball and ramp are in pulled position, this step will be wrong.

3) Tighten cable by lenghtening it to spec. Typically 1/16 - 1/8 gap at lever housing

 

Whiffleboy,

I have the same problem after installing new bars and cables. What was your solution?

Thanks.

 

In case anybody else searches for an answer to this problem:

The solution is the 2nd and 4th posts of this thread.