Replacing the clutch cable: Difference between revisions
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[[Category:Clutch & Transmission]] | [[Category:Clutch & Transmission]] | ||
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If, while doing a routine check, you happen to notice this, consider yourself lucky. Other ways of telling it's time for a new clutch cable include the clutch just not feeling “right” while shifting. Snapping mid-shift is probably the most popular indicator. | If, while doing a routine check, you happen to notice this, consider yourself lucky. Other ways of telling it's time for a new clutch cable include the clutch just not feeling “right” while shifting. Snapping mid-shift is probably the most popular indicator. | ||
[[Image:fray2w.jpg|170px]] | [[Image:fray2w.jpg|170px]] | ||
Needless to say, this clutch cable needed to be replaced. | Needless to say, this clutch cable needed to be replaced. | ||
==Stuff you need== | |||
First, have the new cable on hand. This one was from Kawasaki. | First, have the new cable on hand. This one was from Kawasaki. | ||
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[[Image:2tools.jpg|170px]] | [[Image:2tools.jpg|170px]] | ||
==Taking stuff off the bike== | |||
First, remove the seat. In case you didn't know, the latch is released by the key on the left side panel, just below the seat. | First, remove the seat. In case you didn't know, the latch is released by the key on the left side panel, just below the seat. | ||
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[[Image:4sidescrew.jpg|170px]] | [[Image:4sidescrew.jpg|170px]] | ||
Since you will be removing the fuel tank, you'll need to disconnect the fuel and vacuum lines. | Since you will be removing the fuel tank, you'll need to disconnect the fuel and vacuum lines. Turn the petcock to 'off', pull the petcock vacuum line, then carefully pull the fuel line; a few cc's of fuel will be in the fuel line, so be prepared to pour it into a gas can or something. | ||
[[Image:6fuelline.jpg|170px]] | [[Image:6fuelline.jpg|170px]] | ||
The lines should pull off the petcock after you slide the clamp springs down the lines a little | The lines should pull off the petcock after you slide the clamp springs down the lines a little. The larger line is the fuel. Put a plug in the line to keep dirt out and fuel in. Shown here is just a small machine screw that fits snugly in the line as shown. | ||
[[Image:7lineplug.jpg|170px]] | [[Image:7lineplug.jpg|170px]] | ||
Next, remove the fairing screws from the front of the tank. | Next, remove the fairing screws from the front of the tank. Make sure to see these [http://faq.ninja250.org/wiki/How_do_I_remove_the_fairing%2C_fuel_tank%2C_etc%3F#Warnings_first.2C_AND_PAY_ATTENTION very important warnings] about the upper fairing bolts. Don't mix them up. | ||
[[Image:8fairscrew.jpg|170px]] | [[Image:8fairscrew.jpg|170px]] | ||
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To remove the tank, pull the tank rearward, then up as shown. Be careful if the tank is full. It will be heavy, and sloshing fuel will make the tank unbalanced while moving it. Be careful of the petcock when setting the tank down. It's a good idea to set it on top of a cardboard box, or something else that avoids putting pressure on the petcock. | To remove the tank, pull the tank rearward, then up as shown. Be careful if the tank is full. It will be heavy, and sloshing fuel will make the tank unbalanced while moving it. Be careful of the petcock when setting the tank down. It's a good idea to set it on top of a cardboard box, or something else that avoids putting pressure on the petcock. | ||
[[Image:12tankoff.jpg|170px]] | [[Image:12tankoff.jpg|170px]] | ||
==Removing the cable/installing the new one== | |||
Next, you need to loosen both cable adjusters before you can remove the old cable. | Next, you need to loosen both cable adjusters before you can remove the old cable. | ||
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Now, you must loosen the adjuster at the clutch lever on the engine. The top nut is unscrewed as far up as it will go. The bottom screw must be unscrewed until it comes off the threaded end of the cable, down near the cable boot. | Now, you must loosen the adjuster at the clutch lever on the engine. The top nut is unscrewed as far up as it will go. The bottom screw must be unscrewed until it comes off the threaded end of the cable, down near the cable boot. | ||
[[Image:14adjloose.jpg|170px]] | [[Image:14adjloose.jpg|170px]] | ||
[[Image:14aside.jpg|170px]] | [[Image:14aside.jpg|170px]] | ||
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[[Image:22wiretienew.jpg|170px]] | [[Image:22wiretienew.jpg|170px]] | ||
==Adjusting the new cable== | |||
Make sure the clutch lever is pushed up, removing any play from the lever. | Now you need to [[Adjusting the clutch cable|adjust the new cable]], since both adjusters are loose. The handle bar adjuster should still be backed all the way off. Adjust the clutch end first. | ||
Make sure the clutch lever (at the engine) is pushed up, removing any play from the lever. | |||
[[Image:23leverpush.jpg|170px]] | [[Image:23leverpush.jpg|170px]] | ||
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Once you are satisfied with the adjustment, double check the cable routing. There should be no binding or pulling of the cable when the handlebars are turned. | Once you are satisfied with the adjustment, double check the cable routing. There should be no binding or pulling of the cable when the handlebars are turned. | ||
==Putting everything back together== | |||
Reinstall the fuel tank, making sure the lugs on the bottom of the tank engage the bushings on the frame. | Reinstall the fuel tank, making sure the lugs on the bottom of the tank engage the bushings on the frame. | ||