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[noddy]

My brothers Electra X had a clutch cable break at the engine end. He is having trouble getting the cover off.
He has removed the holding screws, but says it does not want to shift. Is it something else holding it on?
regards Noddy

[papasmurf]

Which cover? The small oval one with two allen screws holding it is in my experience rather firmly attached by the gasket.

[Thunderdird 2]

When checking mine to make sure I had the right spare I gently slid a Stanley blade behind the oval plate and saved the gasket.
I wiped both faces with grease putting the gasket in between on re-assembly, no oil leeks!
Done that on the tappet cover also.
I've read that you need to remove the whole cover to retrieve the broken nipple form inside as you cant have that floating around inside the case, some one might like to advise please?
Terry

[Adrian]

If you catch it quick as the clutch end is starting to unravel the end cover won't have to come off, undo the 18mm hex plug, and careful work with a pair of long nose pliers will unhook the remains of the cable end from the operating lever. You might even get away with this if the end has come adrift completely, so long as it is sitting in the lever end. Otherwise it's kick start off (and gear lever if there's a right-foot shift conversion) to remove the end cover. A.

[Frank]

If he is trying to remove the whole gearbox end cover it can be a bit of a pig. As well as the Allen screws there are two dowels at about 1 and 8 o'clock preventing any rotational movement. No good tapping the cover with a mallet hoping to break the seal. The cover has to come straight off. You can just about get a purchase with a piece of wood passed through from the other side of the bike on the raised bit on top of the cover, then tap that with a hammer to break the gasket seal then gently lever it free.You will destroy the gasket so will need a spare.

[Tim NZ]

Fit the later model inner lever assembly with a stirrup for the cable nipple to pull through.


The early 5 speeds boxes area PITA and they shear the lower nipple of the clutch cable all the time.

[noddy]

Thanks for your advice, it appears that the broken piece of cable has disappeared inside somewhere. Will take the cover off with care to retrieve it.
Job for the weekend, will report back later.
Regards
Noddy

[papasmurf]

Noddy something like this may well be worth buying:-

https://www.king-tool.com/storefront/in ... ex&cPath=4

[noddy]

Job done, nipple removed with a dollop of grease on a thin screwdriver. thanks again for your help.
noddy