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Clutch cable replacement

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  • Clutch cable replacement

    hello, my clutch cable snapped last night on the side of the road. my bike is sitting in a parking lot. i need to replace the cable. this is a xj1100 maxim 1982. does anyone one have any detailed instuctions for a newbie. is this a hard fix. what tools will i need to replace it as it is not at my home. i ordered one today said will be here on friday. please help as i cannot get someone to come to it so i need to do myself.
    thanks
    Steve Josch
    Toronto ontario
    1982 xj1100 maxim owner

  • #2
    Cowboy - Take the rubber boot off at the handlebar, and loosen the big adjuster nut. Remove the two screws and remove the cover plate on the clutch cover. There is a litte soft metal piece that holds the clutch end of the cable in place. Bend it back, and disconnect the end of the cable. Take it loose at the handlebar. Installation is reverse of removal - adjust at the handlebar so you have 1-2mm of play in the lever. Not sure, but you might have to remove the gas tank to get the new one in. Might be a good idea to bring a block of wood and a large prybar if loosening the cable doesn't give you enough to work with. You can lay a 2 X 4 across the footpegs and use a prybar to gently lift the clutch lever to give you enough room to get the cable out.
    Last edited by dbeardslee; 03-25-2009, 12:30 PM.
    I think I have a loose screw behind the handlebars.

    '79 XS11 Standard, Jardine 4/1, Dyna DC1-1 Coils, 145 mains, 45 pilots, plastic floats - 25.7mm, XV920 fuel valves, inline fuel filters, speed bleeders, Mikes XS pods, spade-type fuse block, fork brace, progressive fork springs/shocks, manual petcocks, 750 FD, Venture cam chain tensioner, SS brake lines

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    • #3
      You should only need a cross head screw driver, #2, pliers, needle nose pliers, and a little bit of duct tape.
      Take the rubber boot off at the handlebar, and loosen the big adjuster nut. Remove the two screws and remove the cover plate on the clutch cover. There is a litte soft metal piece that holds the clutch end of the cable in place. Bend it back, and disconnect the end of the cable. Take it loose at the handlebar.
      Once the old cable is loose, tape the handle bar end of the new cable to the engine end of the old cable. Try NOT to make it a big blob, but use the tape to make an "inline" splice. You should then be able to pull the old cable out to the handlebar side, and bring the new cable with it.
      I like to adjust my clutch so I have about 1/4" to 1/3" of movement at the ball end of the clutch lever. Your adjustment may vary, but you MUST have some "free play" at the clutch lever for the clutch to work properly.
      Ray Matteis
      KE6NHG
      XS1100 E '78 (winter project)
      XS1100 SF Bob Jones worked on it!

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