Replacing a clutch cable?

[Glowerss]

During the end of my R test today, what I can only assume happened is my clutch cable snapped (how's that for timing eh? :brick::brick::brick: )

The clutch lever is now slack, and acts as if it's not connected to anything. It's fair to say the clutch isn't engaging.

Am I right in guessing that the clutch cable has snapped and or is no longer functional?

If so, how big/difficult a job is it to replace on a zzr250/ninja 250? Is it something that somebody who's mechanically hamfisted would be able to replace without too much drama?

Any ideas where a good place to buy such a thing would be? Or where on the bike itself you can find out what kind of cable/measurement ect would be required for buying a new one?

Cheers in advance.

[ducatilover]

If it has snapped your lever should move freely (unless it's bound up somewhere)

Easy as pie to replace.
Buy a new one from Kawasaki :yes:

[Glowerss]

If it has snapped your lever should move freely (unless it's bound up somewhere)

Easy as pie to replace.
Buy a new one from Kawasaki :yes:

Aye, the lever moves freely. Good to have a confirmation of diagnosis.

[jellywrestler]

which end is it snapped?

[Glowerss]

which end is it snapped?

Right near the clutch lever. Was poking around a bit and the rubber came straight away. Got about 5-10cm of cable before its gone.

[FJRider]

If it's only the inner cable snapped, and the outer is still in good condition ... some places can fit (build) a new inner. Keep all the bits ... and take them in for an exact re-build.

[Glowerss]

If it's only the inner cable snapped, and the outer is still in good condition ... some places can fit (build) a new inner. Keep all the bits ... and take them in for an exact re-build.

By inner/outter, you mean the rubber tubing around the outside, and the metal cord bit as inner?

Sorry, I've not been riding very long ans am mildly mechanically useless :laugh:

[FJRider]

By inner/outter, you mean the rubber tubing around the outside, and the metal cord bit as inner?

Sorry, I've not been riding very long ans am mildly mechanically useless :laugh:

YES ... and that "Rubber tube" WILL have a coiled (to be flexible) steel inner layer.

[nzspokes]

Did you pass?

[Glowerss]

Did you pass?

Nope. Testing lady said I did perfectly, but as I didn't finish (all that was left was to ride back to the testing station) she couldn't pass me as it was "inconclusive" :no: Not sure why if you do the entire test perfectly they can' send you through if yah break down right at the end, but thems the rules apparently :angry:

Also FJ, is there any specific shop that would rebuild em if the outter is ok? Or will most of em do so?

[jellywrestler]

If it's only the inner cable snapped, and the outer is still in good condition ... some places can fit (build) a new inner. Keep all the bits ... and take them in for an exact re-build.

get a price first.

[nzspokes]

Nope. Testing lady said I did perfectly, but as I didn't finish (all that was left was to ride back to the testing station) she couldn't pass me as it was "inconclusive" :no: Not sure why if you do the entire test perfectly they can' send you through if yah break down right at the end, but thems the rules apparently :angry:

Also FJ, is there any specific shop that would rebuild em if the outter is ok? Or will most of em do so?

Thats shithouse.

The cables an easy job. If I was free in the evenings I would do it for you.

[FJRider]

Also FJ, is there any specific shop that would rebuild em if the outter is ok? Or will most of em do so?

I live in Paradise ... and that's a long way from Jaffa town. Various places do it. Ask an aucklander ...

[FJRider]

get a price first.

I'd find a wrecker first ...

[ducatilover]

Run to eBay, you'll get a new one for around $25nzd.
Second hand is a waste of time, new won't cost much more even at Kawashitty NZ prices.
If you can't find one (highly unlikely) measure yours, I might have one that'll fit 'til you can find another or get a new one made (eBay is still cheaper)

[Glowerss]

Run to eBay, you'll get a new one for around $25nzd.
Second hand is a waste of time, new won't cost much more even at Kawashitty NZ prices.
If you can't find one (highly unlikely) measure yours, I might have one that'll fit 'til you can find another or get a new one made (eBay is still cheaper)

Cheers mate. Appreciate the offer.

Ebays probably a last resort, as bikes my only source of transport. Fortunately I have the old bike im trying to sell in the interim, but it definitely needs to be sorted ASAP.

Hopefully a kawa supplier/dealer nearby has one. Then it'll be off to the interwebs to find out how. Hopefully isn't too difficult, the tangle of wires/cables down looks like a hot mess at the moment.

[ducatilover]

Easy enough, motor end:
Two nuts on a threaded part of the cable sheath, probably 12mm. Slacken it up, pull the cable through
Top end, like the grooves on the two parts of the adjuster up, pull cable out and pop the wee bobbly bit (long day, jargon escapes me)

If that fails, big fucking hammer

[FJRider]

If that fails, big fucking hammer

If it's insured ... chuck it in the tide ...

[FJRider]

Hopefully a kawa supplier/dealer nearby has one. Then it'll be off to the interwebs to find out how. Hopefully isn't too difficult, the tangle of wires/cables down looks like a hot mess at the moment.

Yep ... see how much a new one will cost first.

[Glowerss]

Easy enough, motor end:
Two nuts on a threaded part of the cable sheath, probably 12mm. Slacken it up, pull the cable through
Top end, like the grooves on the two parts of the adjuster up, pull cable out and pop the wee bobbly bit (long day, jargon escapes me)

If that fails, big fucking hammer

:laugh: Big fucking hammer part should be no problem! Cheers, doesn't sound difficult in the least then.Should require minimum dismantling of the bike as well. :wings:

[actungbaby]

[QUOTE=Glowerss;1130410933]During the end of my R test today, what I can only assume happened is my clutch cable snapped (how's that for timing eh? :brick::brick::brick: )

When you get the cable sorted i found with my little honda xl 100 i had to get block wood

And hook up cable to the handle bar then push bit wood onto the lever on the engine to get close

enough to the cable the other end, dont attach the cable to the clutch lever till then

Aslo you know you turn the adjuster circle wheels so line up so the cable just slip out of the mirror

clamp on the handle bars or clip ons whatever you have

[f2dz]

Got mine ordered and replaced by MrMotorcycles in Pukekohe. Was about $60, installed for $20.

Was planning on doing it myself but it broke when I got there and had no tools with me to fix it.

[Glowerss]

Got mine ordered and replaced by MrMotorcycles in Pukekohe. Was about $60, installed for $20.

Was planning on doing it myself but it broke when I got there and had no tools with me to fix it.

Got it in Yesterday. 35$ From Spectrum Motorcycles on the shore. If I wasn't a complete tard could have gotten it sorted in less then an hour. Took me three cuz im a dope :lol: but its all sorted now.

Thanks for the advice in the thread gents.

[ducatilover]

Did you use a big hammer?

[Glowerss]

Did you use a big hammer?

Nearly! Took me better part of an hour and a bit to get the end bit out of the clutch lever. bastard was supposed to just pull out and drop down nice and easy. No matter what I did damn thing would not come out. Was very nearly to the hammer stage! :girlfight:

Turns out ZZRS (or atleast mine does) have adjustable levers, which none of the other kwacka 250s do. And if it's set to 1 2 or 3 (like mine was) the lever doesn't open all the way leaving an invisible 1mm bit blocking the nipple bit of the clutch cable from coming out. Have to slot it to 5 to get the thing to come out :mad:

No dramas once I got that sorted out. It was a close thing though!

[ducatilover]

You probably have the same levers as my ZZR then, I've never noticed taking the cable out :lol: must be my awesome skillz

[Akzle]

If so, how big/difficult a job is it to replace on a zzr250/ninja 250? Is it something that somebody who's mechanically hamfisted would be able to replace without too much drama?

Any ideas where a good place to buy such a thing would be? Or where on the bike itself you can find out what kind of cable/measurement ect would be required for buying a new one?

Cheers in advance.

not very. (hard)
cables can be uni-fit but prob best with stock replacement, or can have one made up (dont know where in AKL)