Bandit Alley

MODEL SPECIFIC => SUZUKI BANDIT 250 & 400 => Topic started by: dvelasq on May 12, 2006, 08:13:49 PM

Title: clutch repair
Post by: dvelasq on May 12, 2006, 08:13:49 PM: how hard is it to replace the clutch cable. My cable broke right were the handle is. Im new to this so can someone help. What do I need?
Title: clutch repair
Post by: stormi on May 12, 2006, 09:52:20 PM: Should be pretty easy, as long as it's just the cable.

You'll likely have to lift the tank to fish the old one out. Just route the new one to where the old one was.

when you get down to the bottom left of the bike, it should be reasonably self-explanatory as to how to change out that part of the cable. (there will be a "clutch release cover" to remove)

Make sure you adjust the cable after you install the new one. The procedure should be in the service manual. Chapter 2 page 10.

If you don't have the manual, a search of this site should help you.
Title: clutch repair
Post by: duane on May 13, 2006, 12:38:16 AM: A hint here, and Stormi touched on it, route your new cable while the old one is still in place so you can see exaclty where it goes. Once it's in, pull the old one. Replacing this cable is not too tough.
Title: clutch repair
Post by: dvelasq on May 13, 2006, 09:27:23 PM: How does the line stay into the actual handle. Is there some piece I need.
Title: clutch repair
Post by: stormi on May 14, 2006, 04:13:58 PM: The line should have a ball on the end of it. Where did the cable break?

This is a sketch of the cable. Ignore where it looks like the cable is in two parts. That's just how the microfiche is done.
(http://www.stormi.ca/clutch_cable.jpg)

The cable routes like this, you may have to peel ( carefully) back the rubber cover to see this on your own bike. :
(http://www.stormi.ca/cable_route.jpg)

And the end of the cable goes in here, as seen from the bottom:
(http://www.stormi.ca/cable_end.jpg)
(sorry that one's out of focus, it was a fast shot and an awkward angle. )
Title: clutch repair
Post by: dvelasq on May 14, 2006, 05:05:17 PM: Thanks that helps alot. The end of the wire that goes into the lever. How does that stay in there. Is there a bolt or screw that I need. The wire just broke right at the brake lever, its just not attached to the actual brake lever.
Title: clutch repair
Post by: stormi on May 14, 2006, 06:17:38 PM: It's held in by tension on the wire.

Have you looked at the way this is set up? It's just like a mountain bike is set up. Go out and have a look at it, and you'll see that I've shown you what the cable looks like installed.

There is no screw on mine, and this is how it's designed to be.

And that's not the brake lever.
Title: clutch repair
Post by: dvelasq on May 15, 2006, 09:22:51 PM: ok the wire that goes to the actual handle that you squeeze, is it suppose to be attached to something so that it stays inside the handle. I have it all set up, but that round circle under the metal bar in picture 3 looks like it has the wire hooked into it somehow with some circle piece. On my bike it is just an empty space. Is this some attachment I need? The cable did break while riding so maybe it fell off.[/code]
Title: clutch repair
Post by: Red01 on May 16, 2006, 10:53:09 AM: The cylindrical end piece in the handle is attached permanently to the cable by the manufacturer. If your cable doesn't have it, you need a new cable.

If you're talking about the knurled circular part on the threaded adjuster, it's the lock nut. You need that to make the adjuster stay put.
Title: clutch repair
Post by: magicGoose on May 16, 2006, 10:53:54 AM: Yep, it broke off and fell out. If you look carefully at the diagram ( not the photographs ) that Stormi posted, you can see there is a little nubbin on both ends of the cable. These are not removable unless they break off. A new cable is all you need, everything is part of the assembly. When you see it, it will all become clear to you.
:beers:
Regards,
Steve
Title: clutch repair
Post by: dvelasq on May 16, 2006, 03:46:22 PM: thanks alot now I get it.
Title: clutch repair
Post by: dvelasq on May 16, 2006, 03:53:03 PM: Is there a specific type of cable i am suppose to buy Size? or Brand?
Title: clutch repair
Post by: Red01 on May 16, 2006, 04:20:28 PM: Yes. The Clutch cable assy for your year/model of bike.
Title: clutch repair
Post by: dvelasq on May 20, 2006, 01:56:34 PM: What do I need to do to take out the end that is going into the engine. Do I need to take off the whole side of that piece that it goes into or is it able to come out somehow. Also I dont have a manual, what type of adjustments are important to know? Thanks again for the help.
Title: clutch repair
Post by: BrianM on May 20, 2006, 02:46:13 PM: The manual is available in the Members section of this board, it's free for download and should answer all of your questions as to how it's attached. If not, look at the microfiche break-out of the clutch, available on any number of different websides... it's Really very simple if you just go give it a shot.
Title: clutch repair
Post by: dvelasq on May 23, 2006, 07:50:58 PM: What do I need to know about adjusting the screw that goes into the clutch. Is there a certain distance it needs to be in or out.