Hitchcocks Forum

Hello all

Clutch cable snapped which is a bit odd bearing in mind only done 2200KM on Thunderbird 350 5Speed (Indian) reg: 2003 - Ordered universal kit and connected up to clutch lever all good BUT now realise that the Barrel the other end will not fit through the External Casing Cable Adjuster - I presume that I will have to unsolder barrel (if possible to do?) or cut barrel off and attach a solderless barrel, or am I missing a trick here? - Any advice greatly welcome - Thank you

If you're careful you might be able to cut a slot along the length of the M8 threaded adjuster, hopefully the M8 locknut with fit over the nipple... A.

Thanks Adrian - Nice thought - In my naivety thought universal cable kit would have worked - Special clutch cable needed opted for (UK Version) and have also been advised to replace 5Speed Gearbox Clutch cable arm to modified design (reason cable snapped in the first place) - Think I will call Hitchcocks first next time, before making an order! - Thank you anyway for your suggestion - Thanks to Hitchcock's for their help and advice too!

The old style clutch cable arm has a habit of eating cable ends, so fitting the revised version is a good move. Shame it doesn't stop cables snapping at the handlebar end, though...

Glad I am not the only one still having cables breaking at the handlebar end. Recently removed the updated operating arm and refitted it with washers between the assembly and the case. It appears that the end of the arm can come into contact with the casing causing a jam. Still not convinced though, I carry a spare cable just in case.

The time has come to investigate hydraulic conversion. Our hosts have one but only for the four speed boxes, but we're going to have to go off-catalogue for this. I think someone has converted the five speed box using Chinese pit-bike parts, if that doesn't appeal the Venhill web site has various kits.

I have been looking at modifying a gearbox cover to accept a japanese style clutch pusher with an external operating arm for the cable to go on. At least a cable change will be quicker and easier. Dubious about a hydraulic system, at the moment we have a known weak link.

Maybe helpful to some to X-Ref: "sudden clutch cable slack" - Started at 08:41am on the 23rd June, 2015 by papasmurf

I also have a 5 Speed 350cc RE Thunderbird.

So far, I have not had any problems with cables.

Thanks for the info. I will have to think about buying spare cables and possibly a different style lever.

It's worth carrying a spare clutch cable with whatever tools you may have with you. A.