1. Some members were not receiving emails sent from XJbikes.com. For example: "Forgot your password?" function to reset your password would not send email to some members. I believe this has been resolved now. Please use "Contact Us" form (see page footer link) if you still have email issues. SnoSheriff

    Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

Clutch adjustment issues -- funky clip at the cable end

Discussion in 'XJ Technical Chat' started by clhannah, Aug 9, 2008.

  1. clhannah

    clhannah Member

    Messages:
    101
    Likes Received:
    0
    Trophy Points:
    16
    Location:
    Portland, OR
    [​IMG]
    I think this may be causing my adjustment issues. it is a cylindrical clip with a sort of spiral cut-out that slips over the cable end. My guess is the previous owner used the wrong cable and this clip is designed to take up the space. It shifts around and seems to add just enough slop to make the clutch feel inconsistent. Can someone confirm this is incorrect so I can order a replacement from chacal?
    Y'all are awesome!
     
  2. clhannah

    clhannah Member

    Messages:
    101
    Likes Received:
    0
    Trophy Points:
    16
    Location:
    Portland, OR
    bump -- can someone verify this is not correct before I order a new cable please?
     
  3. bigfitz52

    bigfitz52 Well-Known Member Premium Member

    Messages:
    21,283
    Likes Received:
    420
    Trophy Points:
    83
    Location:
    Rural SE Michigan 60 miles N of Motown
    They all have that little teflon sleeve to begin with, it's to make it operate smoothly and not let the barrel on the cable wear out the hole in the lever. New cables come with 'em, I don't know if I've ever seen them avail separately. If you're having clutch adjustment issues, I hightly doubt the little teflon sleeve is the cause of your problem. What's the exact issue?
     
  4. RickCoMatic

    RickCoMatic Well-Known Member

    Messages:
    13,842
    Likes Received:
    67
    Trophy Points:
    48
    Location:
    Massachusetts, Billerica
    There's supposed to be a Slotted Bushing surrounding the Lead Bullet on the end of the Cable.

    Its there to allow the Bullet to swivel and pivot within the cavity on the Clutch Lever ... rather than there a tight fit and friction that would cause the Bullet NOT to FLOAT and ... after just a few times bending the actual cable -- back-and-forth -- cause it to break right off and leave you stranded with a broken Clutch Cable.
     
  5. clhannah

    clhannah Member

    Messages:
    101
    Likes Received:
    0
    Trophy Points:
    16
    Location:
    Portland, OR
    thanks guys. the slotted bushing slips out of place (actually hangs half-way out of the hole) and that allows the "lead bullet" to move, creating slack. Since it is supposed to be there I will try and find a way to keep it in place, since the bike shifts OK when it is.

    Cheers!
     
  6. wizard

    wizard Active Member

    Messages:
    5,282
    Likes Received:
    26
    Trophy Points:
    38
    Location:
    DEVON ENGLAND
    sounds like you're neoprene bush has broken, it should be easy to get a new one, try a bicycle shop.
     
  7. bigfitz52

    bigfitz52 Well-Known Member Premium Member

    Messages:
    21,283
    Likes Received:
    420
    Trophy Points:
    83
    Location:
    Rural SE Michigan 60 miles N of Motown
    Try flipping it over, and ask Chacal if he can supply separately. I just don't know how you'd get it on there. A lot of aftermarket cables don't have them, relying on actual LUBRICATION (!) to prevent said binding...or you might want to go ahead and get a new clutch cable which will have the little bushing on it, intact. Yours looks a bit buggered up...
     
  8. wizard

    wizard Active Member

    Messages:
    5,282
    Likes Received:
    26
    Trophy Points:
    38
    Location:
    DEVON ENGLAND
    there is a long slot in the bush, fitz, that's how they get it on in the first place.
     
  9. Polock

    Polock Well-Known Member

    Messages:
    9,751
    Likes Received:
    2,097
    Trophy Points:
    113
    Location:
    Beaver Falls, PA
    looks like you have no freeplay at all and with the locking ring right up on the perch is seems like you were trying to get some, does the clutch slip?
     
  10. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

    Messages:
    9,243
    Likes Received:
    2,021
    Trophy Points:
    113
    Location:
    The room where it happened
    All original OEM cables come with that nylon/teflon bushing installed on the clutch cable lever end, but it is non-removable......it is installed BEFORE the barrel (or bullet) end is crimped onto the cable and althoutgh it is slotted, the slots do not go to the outer edge of the bushing, thus no way to remove the bushing (nor install a new one).

    All aftermarket cables use a larger diameter barrel (or "bullet") on the clutch cables that matches the the O.D. size of the original sleeved bullet.....and thus no nylon sleeve. I've never heard of a problem with them binding or seizing up, although I suppose that without periodic lubrication, that is a possibility. In both the case of the OEM and the aftermarket cables, the diameter of the bullet (or bullet-with-sleeve) is smaller than the diameter of the lever bore---it is not a press-fit.
     
  11. wizard

    wizard Active Member

    Messages:
    5,282
    Likes Received:
    26
    Trophy Points:
    38
    Location:
    DEVON ENGLAND
    how can you tell that from that picture?
     
  12. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

    Messages:
    9,243
    Likes Received:
    2,021
    Trophy Points:
    113
    Location:
    The room where it happened
    He can't, but little known to most members, Polock is psychic!! :D
     
  13. clhannah

    clhannah Member

    Messages:
    101
    Likes Received:
    0
    Trophy Points:
    16
    Location:
    Portland, OR
    quick followup. Chacal sold me an aftermarket cable without the bushing (larger bullet) and the shifting is infinitely better. The cable is slightly longer, but thanks to reading earlier posts I knew to rotate the clutch arm on the spindle a few splines. Highly recommend this $16 10 minute job. (I used triflo -- I hope that was a good call!)

    And to Polock, I was dancing between slippage and bucking, and now it's smooth as silk.
     
  14. RickCoMatic

    RickCoMatic Well-Known Member

    Messages:
    13,842
    Likes Received:
    67
    Trophy Points:
    48
    Location:
    Massachusetts, Billerica
    Send-in the next patient!
     

Share This Page