| Author | Message | ||
     Luxor |
Just giving you guys a heads up. I just did the "Break the cable threads off in the primary" thing. Funny part is that I was explaining to my dad how it could happen and POW, twisted clean off. Had no trouble removing the broken threads and the primary cover is fine. Only thing I can think of is that I have had the cable out 3 times, and the threads were stretched and weakened by the 4th and fatal install. I was only an hour away from firing her up after 6 months in parts. Oh well, live and learn. | ||
| Mr2shim |
I feel your pain. Happened to me a few weeks ago. It sucks. Already have another cable? I have a spare that I bought off ebay that I'm not going to use. (Message edited by mr2shim on April 20, 2008) | ||
| Spatten1 |
Ingenious design, isn't it. | ||
| Teeps |
Spatten1 Posted on Sunday, April 20, 2008 - 04:53 pm: Ingenious design, isn't it. It's a piss poor design if you ask me. AL at American Sport Bike was kind enough to explain, to me, how fragile this part is and how he installs them, without mishap. I suggest using sealant on the threads. And only tighten until the fitting bottoms on the case. | ||
| Manimal |
In terms of sealant. Is medium strength Loctite a good choice? Or is there something else that would be better? | ||
| Starter |
threebond works a treat | ||
| Luxor |
Thanks for the offer Mr2Shim, but I already have 2 on order. You might want to keep your spare just in case.  Again, thanks. What a great place to hang out and talk Buells, with a bunch of GREAT people. | ||
| Jos51700 |
"a bunch of GREAT people." I'll second that. | ||
| Mr2shim |
Dumbest clutch cable design ever. Guess they used up all the brains designing the frame, swing arm ZTL.  | ||
| M1combat |
Yeah... It's the design that's dumb. | ||
| Corporatemonkey |
I know this clutch cable issue has been brought up before. But is the breakage based on use (number of pulls), age, or is just a freak occurrence? I am curious if replacing the clutch cable should be my long term service list. Last thing I want to deal with a broken cable. | ||
| Spatten1 |
CABLE BREAKAGE: The lever is set up at a bad angle that can bend the cable end and break the strands. Keep the cable end in the lever greased to help it pivot in the lever and prevent the cable from bending. BREAKAGE ON INSTALLATION: This is what he is talking about above, it happens at the fitting that goes into the primary cover when being installed. You have to install that end first so you are not putting too much pressure on the fitting when screwing it in. Then you feed the cable up to the lever. I think it's a ••••••• design for a different reason. One more place for oil to leak out and water to get in. It should be an external cable with an actuation shaft and seal like Japanese bikes- a much better design than the Harley guys came up with in 1955 for this engine. | ||
| Newbolt |
I learned the hard way that the cable end is easy to break. I snugged it up to the housing and was giving it a quarter turn to insure that it was tight and the end snapped. At let all the pieces came out easily. I was more careful the second time and had no problem. Once it was all together I used some clear silicone around the end to keep everything in. No leaks so far. | ||
| M1combat |
A 1/4 of a turn??? Holy crap. No wonder it broke. |
