Clutch cable frustration

Buckets81 · Post by **Buckets81** » Sun Aug 24, 2014 12:09 pm

I'm having some issues and I'm about at the end of my rope. But what's new. When I originally put the bike together, I ordered a full set of cables from Thailand. They worked perfectly for a while but I only got about 1200 miles out of the cheap, thin clutch cable before it snapped. I've tried ordering new cables from Ebay with absolutely no luck. The first one I ordered was one of these:

http://www.ebay.com/itm/Honda-CA92-CA95 ... 1f&vxp=mtr

which I thought would work correctly since I was under the impression that the cables were the same between the early and late bikes. It was too short. It must have been for a low bar bike. I modified it and sort of got it to work but I couldn't keep it adjusted properly. Then I ordered one of these:

http://www.ebay.com/itm/New-Honda-CA95- ... 92&vxp=mtr

and it is WAY too long. It adjusts properly but it has big kinks right before the hole under the gas tank and right after is exits the frame and it is too hard to pull for the bike to be rideable.

I guess I was just wondering if anyone knew where I could get a new cable of reasonable quality (trying to avoid another Thailand cable) that will fit the bike properly. Is Ohio Cycle going to be my best bet? If so, I guess I'll get the carrier pigeon ready and try to order from them.

Spokes · Post by **Spokes** » Sun Aug 24, 2014 2:14 pm

What year is your bike?

From my experience, 1964 & 1965's had a hard elbow at the clutch handle.

Buckets81 · Post by **Buckets81** » Sun Aug 24, 2014 6:15 pm

Spokes wrote:What year is your bike?

From my experience, 1964 & 1965's had a hard elbow at the clutch handle.

Mine is a '65. The Thailand cable I bought had the hard elbow and neither of the replacements did.

ByTheLake · Post by **ByTheLake** » Mon Aug 25, 2014 3:49 am

I got about 650 miles out of my clutch cable before it snapped at the top, about 10 miles from home. I had to push-start it, then do clutchless shifts to get back home. My clutch has always been hard to pull, which is likely a factor. I've lubed the clutch actuator, lubed the cable, but it's made no difference. The cable routing is correct, with no sharp bends. The clutch springs are original. I'm assuming that my new clutch cable will have a similar lifespan.

Spokes · Post by **Spokes** » Mon Aug 25, 2014 4:11 am

I will look in my spare parts box. I may have a good used original clutch cable.

BTL, I found the reason for the hard clutch pull. The rotating auger/actuator has sharp edges. When you pull the clutch in, you have metal to metal contact between the male/female parts.

I used a de-burring wheel from our T&D dept. to smooth out the edges of the male auger. My clutch is smooth as silk.

If both of you guys are interested, just send me your clutch adjuster/auger, both male & female parts, and I will smooth them out and send them back (with some special grease)

PM if interested!

ByTheLake · Post by **ByTheLake** » Mon Aug 25, 2014 12:08 pm

Spokes wrote:I will look in my spare parts box. I may have a good used original clutch cable.

BTL, I found the reason for the hard clutch pull. The rotating auger/actuator has sharp edges. When you pull the clutch in, you have metal to metal contact between the male/female parts.

I used a de-burring wheel from our T&D dept. to smooth out the edges of the male auger. My clutch is smooth as silk.

If both of you guys are interested, just send me your clutch adjuster/auger, both male & female parts, and I will smooth them out and send them back (with some special grease)

PM if interested!

This is encouraging, Chip. Thanks for the information.

I'll pull the mechanism out the next chance I get and do the same.

Buckets81 · Post by **Buckets81** » Mon Aug 25, 2014 5:43 pm

I have access to the tools as well and will also clean mine up. Thanks for the great tip. My brother came over today and rerouted mine and it is possible to pull with one hand now. I think I'll order a couple of Thailand cables so I have a spare for when one snaps and I'll debur the augur and see how that works.

Thanks for the response.

Spokes · Post by **Spokes** » Mon Aug 25, 2014 6:08 pm

Always glad to help. I don't have an old one like I thought, but if I needed a spare or a good used example this one would work http://www.ebay.com/itm/64-HONDA-CA95-C ... 02&vxp=mtr

I would flush the casing out with some WD40, re-oil it with some quality gun oil or 3 in 1 oil, shine the elbow on my buffing wheel or paint it bright silver. Chances are it will outlast any Thai cable.

grubsie · Post by **grubsie** » Mon Aug 25, 2014 6:26 pm

Buckets81

Just an FYI. . The second cable you linked that you had big kinks in is for the early CA's. (Early 63's and earlier) I am surprised you found one. When I was looking, I had to wait quite a while to get the correct NOS one for my early '63. You need the cable with the hard bend.