Question about replacing clutch cable on '90 K100LT - K-Bikes.com - Excellence in Motion
 
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post #1 of 3 (permalink) Old Aug 13th, 2010, 5:31 pm Thread Starter
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Join Date: Nov 2007
Location: Toronto, Ontario, Canada
Posts: 9
Question about replacing clutch cable on '90 K100LT

Hi there,
I am replacing my clutch cable on my '90 K100LT, I've re thread it and attached it at the hand lever end, but can't figure out how to get the old one with the rubber protector out from the holder at the back end and then, of course, how to get the new one through with out destroying the nice new rubber cover.
Any suggestions would be greatly appreciated, my bike is now in pieces in my garage waiting for me to finish this job so I can get back on the road.
Thanks

SPARKY
1990 K100LT
1977 CB750F
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post #2 of 3 (permalink) Old Aug 20th, 2010, 1:33 am
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Join Date: Jun 2010
Location: Ft. Lauderdale, Florida, USA
Posts: 6
Cool Lube that rubber...

Sparky,

I just did a couple of these and here are some hints.

First spray some WD40 on the bottom rubber (use butter or any oil).

Adjust your cable length screw at the handle bar all the way in for maximum length.

Then I use a 1/2" Drive Ratchet to pry the clutch lever up and away from the exhaust. Now you can easily release the cable at the clutch end by hand.

Now for the tricky rubber; I used a pair of needle nose pliers to grab and gently pull the rubber up through the larger forward hole. Then use you fingers to milk the rest through as best you can (you might need those pliers again). My rubber came out unscathed.

Now for a neat trick: I used piano wire (you might also try a wire tie) to attach the new wire to the old one at the trans end and when I pulled the old cable out at the triple tree my new cable has made the journey through the engine compartment without even having to remove any components.

Good Luck..
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post #3 of 3 (permalink) Old Aug 20th, 2010, 10:32 am
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Join Date: May 2010
Location: DC, ,
Posts: 157
Depending on how aggressive you want to be getting the old one off, I just cut mine out after screwing around with it.

As far as getting the little boot back through near the exhaust, its a pain in the ass. Must have spent 15 minutes f-ing around with it. Lube is the key , keep it well coated and then push/pull it until you can get enough through to grab it with needle nose pliers. With a little coaxing you can get it through intact...

Also, in the handle part there is a felt holder that is receded in the handle, check the oem part diagrams. Part 32721231610... I realized that mine was missing when I changed the cable and caused the cable to rub and eventually fail. Also keep the nipple holder lubed...

------------------------------------------------------------------------------------
Current: 1985 K100RT Stripped.
See it here DC to Gaspe

Past: 1985 K100
See it here on my trip from DC to Panama
DC to Panama City

Last edited by lukeman; Aug 20th, 2010 at 10:41 am.
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