Forum

[sofiaspin]

Just a precautionary question - clutch cable snapped leaving the nipple in the gearbox.
I cant see it, - so is it OK to leave gearbox alone and allow the internals to chew up the small piece of metal - or should I strip?

[Shane]

Hi,

Is it 4 or 5 speed?

[sofiaspin]

4 speed 2008 classic electric start prob one of last pre units before efi. Complicated by fact previous owner - who did an astonishing job - converted to the 50s look so it has 800mm wide bars (not hosts) and 50s style levers without adjusters. So only adjustment is by mid-cable adjuster - and at the push rod end. I got the bike 4 weeks ago and was not happy with the tough pull on the lever. So I cut the cable ties, rerouted it - not to much effect I have to say - and lubed the cable. It was perfectly serviceable but compared to my old 2004 es 4 speed classic, and indeed efi woodsman - a hard 'pull. I suspect routing is the issue. But I have been reading a long thread about cable breakages/nipples etc with Grunda and Johnny Singles amongst others to the fore - and it is difficult to draw a clear line on this, most basic of, issues - a clutch cable! I have ordered a new one from our hosts, a long one to match the bars, and will go through the instal carefully. Ripping open the primary side is the next option to see if there is resistance on plates etc

[PeteF]

Well, the debris wouldn't get into the gears. If it did it could cause major damage. As it is, it will only get into the outer case and, though it could jam the gear change mechanism it will probably fall to the bottom. It's quite easy to remove the outer cover and recover it. When you replace the cable, look carefully to see if it's chafing anywhere. Cables don't just break.

[sofiaspin]

Thanks Pete F - sound advice. I am pretty sure it is down to cable routing. There was chaffing at the cable end, suggesting poorly aligned entry to the gearbox so a problem waiting to surface on purchase.

[John M]

If you have a super-heavy clutch someone may have fitted heavy duty springs.

[Nettshubby]

You could get a nylon lined cable, I believe Venhill do them.

[sofiaspin]

Received British made long cable from hosts today, a day later - usual excellent service. Much better than the one on the bike that failed - the Brit version has bigger and stronger nipples at either end, and the cable itself looks better quality. Pulls more easily and allows for more mid cable adjustment. Result.