clutch cable

[cowboy5]

hello. i got hit by a truck the other day on my 82 xj1100 maxim. bike did pretty good, i didnt though but i will mend.
i broke my lights (all of them) which ni have repaired. scratched some paint which is getting repaired today. and broke the clutch cable and mirrors. i have an extra set of mirrors.

my problem is the clutch cable. it broke in the handgrip. the little metal piece cam off on the end. i have tried to get a new one. I am in canada and my riding season is maybe good for 3-4 more weeks. to order a new cable will take 6-8 weeks. does anyone know a way to put the little metal piece back on, or a nut or something i could put on the wire that will compression grip it and stay on til my new cable comes?
any ideas would be really apreaciated as i am riding a bus right now and takes 3 hours to get to work

thanks
steve

[mitch]

Scrap yards

Have you checked motorcycle scrap yards in your area? the xs cable is the same i think.

[CatatonicBug]

Ouch! How scary! Sorry to hear about the accident. I don't really have any input about the cable, but doesn't your insurance cover that stuff? I know mine does. I just drop it off at their facility, and they give me a rental car until it's fixed.

[mitch]

Solder

Try to drill a hole thru it then slide the cable in and solder it ...worth a try

[cowboy5]

thanks to everyone. any other suggestions would also be appreciated. i will try to drill a hole though. I didnt have collision coverage just liability as the bike cost me less than they wanted for insurance

[barberad]

http://www.bikebandit.com/cables-for...106?m=8192&t=1

XJ and Xs cables are not the same.
Made by motion pro. Has them in stock. Usually ships in 24 hours. $14.35 USD

Dan

[Tdog]

Canadian Tire

Hi, hope you're better soon!
Can Tire has "cable stop clamps" (Brass barrels with set screws threaded in from each end) in the Help section near the auto parts counter. The stock #s on my pack are 03336 and 024-5322-8. One pkg contains 5 in ass'td sizes. HTH
Regards,
Tom

[fredintoon]

It's a real chore but here's how it's done.

Hi Cowboy,
if you just can't wait for the new cable to get to you and you can't find one at a bike breaker's, here's how to fix the broken one. The nipple that broke off is cast in place and is made of a zinc-based alloy. You can't drill the cable stub out of it because the wire is harder than the nipple so the drill will wander off and you can't solder to zinc anyway. Throw the broken nipple away. You will have to find a replacement brass nipple which is really hard to do these days. Perhaps an old-fashioned bike shop near you still stocks them or at least one of those emergency nipples with a pinch screw. Those don't work as advertised because the pinch screw can't grip the cable hard enough but you can solder them in place. But most likely you will have to make one. Get a length of 3/8" diameter brass rod and drill through it crossways to just clear the cable diameter. Now drill the hole you just made half way through about 5/16" diameter. Cut the new nipple to length. Cut back the cable outer sheath so the right amount of cable sticks out. Put the end of the cable through the new nipple with the overbore pointing away from the cable's main length and use two pairs of mini-pliers to spread the very end of the cable's individual wires out like a tiny little chimney sweep's brush. Grip the nipple in a vise and slather it and the cable end with soldering flux paste. Heat the nipple with a Bernz torch and dab solder wire onto the sweep's brush until it melts and runs into the nipple. Pull down on the cable until the sweep's brush end moves down into the 5/16" overbore. Let it cool, file off any solder overflow and she's fixed.
And as I tell all first time solderers, if the molten solder runs onto your skin don't scream like a girl. Though you are allowed to make a deep manly groan.

[81xsproject]

Clutch cable...? What clutch cable?

[cowboy5]

thanks

thanks all. went to canadian tire got the clamps and it seems to be working well menough until my new cable comes. was easy to do, just needed to make the hole in the brass a little larger

[Ivan]

thanks all. went to canadian tire got the clamps and it seems to be working well menough until my new cable comes. was easy to do, just needed to make the hole in the brass a little larger

The hole in your what?

Oh the hole in your brass.