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Author Topic: new, premium clutch cable/2007 AVL, 5-spd  (Read 400 times)

wiekingderviking

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new, premium clutch cable/2007 AVL, 5-spd
« on: June 01, 2013, 07:01:51 PM »
I  installed "higher and back" handlebars....I've just installed new, "premium", longer clutch cable.

I'm an over-confident, experienced wrencher  and I do not seem to find a good ROUTE for the cable from gearbox to handlebar lever. "who in the heck remembers WHERE the clutch originally ran?!"
 STIFF, nasty operation.  Before, the shorter original cable was too short and kinking but it's operation was great!

Please, people with AVL, 5 spd gearboxes- please detail the EXACT route for your clutch cable "up under the tank, around(or not) the steering head, thru the casquette(or not) and where does it exit from the front of the bike to the clutch handle"??
Too many variables....
History:
1947 BSA 500cc flat tracker
1960 Matchless 350cc single
1960's Honda CB450
1965 R60 BMW
1960's Matchless "Typhoon" 500cc
1986 Yamaha 500cc single
BMW K75
2007 Royal Enfield Electra, AVL

Machismo

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Re: new, premium clutch cable/2007 AVL, 5-spd
« Reply #1 on: June 02, 2013, 09:28:17 AM »
Here is how mine runs:
Through the casquette hole >RHS of the steering head, alongside the wiring loom > underneath the tank > behind the left top of the air box > attach to the gear box end.

Hope this helps.

wiekingderviking

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Re: new, premium clutch cable/2007 AVL, 5-spd
« Reply #2 on: June 02, 2013, 03:35:57 PM »
Hey! this info on cable routing helps!!!
I found the variations were endless, with each requiring dismounting fuel line and tank...

I thank you!!
Bob in Ellensburg
History:
1947 BSA 500cc flat tracker
1960 Matchless 350cc single
1960's Honda CB450
1965 R60 BMW
1960's Matchless "Typhoon" 500cc
1986 Yamaha 500cc single
BMW K75
2007 Royal Enfield Electra, AVL

boggy

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Re: new, premium clutch cable/2007 AVL, 5-spd
« Reply #3 on: June 02, 2013, 03:56:25 PM »
Hey Bob,
I just bought the premium cable for my AVL as a backup.  Right after installing the regular one, the rubber sheath split where it bends into the casquette because of my clubman bars.  I snap a cable right at the lever end every few thousand miles so I thought I'd give the premium a go for the next time it snaps.

What are your thoughts after routing it correctly?  It looked heavy duty but I was worried it would feel heavy too. Maybe I'll go back to the regular one and buy double.

Thanks.
Boggy
2007 AVL
2006 DRZ400SM

Arizoni

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Re: new, premium clutch cable/2007 AVL, 5-spd
« Reply #4 on: June 02, 2013, 05:52:44 PM »
Any time you have to bend the cable sharply it's going to get a lot more resistance to moving so it's under a lot more load than it's designed for.

Maybe it would be better if you didn't bend it to go thru the casquette and found a less twisty way to install it.
Yah, it would be out in the wind and might flop around a bit but I bet it would last a lot longer.
Maybe a few black nylon zip ties could be used to minimize the flopping?
Jim
2011 G5 Deluxe
1999 Miata 10th Anniversary

Techmaven

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Re: new, premium clutch cable/2007 AVL, 5-spd
« Reply #5 on: June 02, 2013, 08:59:15 PM »
I replaced mine today with what I believe is the standard cable..It came with a box of spares when I bought the bike..Routed though the casquette and down under the tank, along where the wire bundle is, then down in front of the sidecover and into the gearbox..I zip tied it to the loom of wires to avoid "floppage". What a pain in the neck to get the old cable disconnected at the gearbox end! Lets hope it lasts a good while!
« Last Edit: June 03, 2013, 12:48:56 AM by Techmaven »