ADVrider

Go Back   ADVrider > Bikes > Thumpers
User Name
Password
Register Inmates Photos Site Rules Search Today's Posts Mark Forums Read

Reply
 
Thread Tools Search this Thread Display Modes
Old 03-27-2006, 12:01 PM   #1
Colemanfu OP
King of all manfu
 
Colemanfu's Avatar
 
Joined: Jan 2006
Location: DAYTONA USA
Oddometer: 3,330
KTM LC4 quick broke clutch cable fix...

Don't know if it's the hills or just a yearly fix but for the 3rd year in a row that my clutch cable has let go on my trip to the MT's. I only get up there 2 times a year so I want to make the most of the trip. 1st time I parked the bike, 2nd had some rig with a screw 3rd no worries. I have got pretty good about making a road fix to get home but this time I did not let it spoil the fun. Had 2 full day left when it broke and rode with this fix - no problem. Held like a champ. I wonder if there is anything stronger than stock? I'll let the pix do the talking - I added the TY strap to hold the vice grips back and keep the cable in the stock slot.


Ouch - that looks like another broken clutch cable!
Attached Images
 
__________________
Guns keep society safe.

Colemanfu screwed with this post 03-27-2006 at 12:04 PM Reason: add
Colemanfu is offline   Reply With Quote
Old 03-27-2006, 12:01 PM   #2
Colemanfu OP
King of all manfu
 
Colemanfu's Avatar
 
Joined: Jan 2006
Location: DAYTONA USA
Oddometer: 3,330
That thing looks broke - time to fix her up! You can see that I removed the boot and the stock adjustable spacer. That gives the length to grap the cable.
Attached Images
 
__________________
Guns keep society safe.

Colemanfu screwed with this post 03-27-2006 at 12:06 PM Reason: addd
Colemanfu is offline   Reply With Quote
Old 03-27-2006, 12:02 PM   #3
Colemanfu OP
King of all manfu
 
Colemanfu's Avatar
 
Joined: Jan 2006
Location: DAYTONA USA
Oddometer: 3,330
Fix held like a champ and lasted for 2 more days in the hills. I ran the TY strap through the vice grips so I they did come loose I would not loose them. It also pulled every thing back and out of the way.
Attached Images
 
__________________
Guns keep society safe.
Colemanfu is offline   Reply With Quote
Old 03-27-2006, 12:44 PM   #4
Airhead
More human than human
 
Airhead's Avatar
 
Joined: Nov 2004
Location: Fear and Loathing in Maine
Oddometer: 2,099
Nice! Nothing like fixing something yourself with just what you have on hand. Makes the riding even more rewarding...

__________________
'05.5 KTM 950 Adventure
2008 KTM 450 EXC-R
All Orange, Baby!
Airhead is offline   Reply With Quote
Old 03-27-2006, 01:40 PM   #5
GT-STMC
Gnarly Adventurer
 
Joined: May 2004
Location: Weslaco, TX
Oddometer: 108
Great idea, thanks.
I've had mine break twice 30+ miles from home and just rode back trying to never stop....., a real pain going through tolls and international customs. I'll start carrying something small that I can clamp onto the cable now as well. Vice grips worked, but there'll be something smaller, even a 1/2 in bolt, 2 washers and a nut should do it.
__________________
www.RGVCycleStuff.com

2001 KTM 640 Adventure, 1997 Kawasaki Ninja (converted to "street fighter" form)
"Sex....., Money......, Horsepower......, too much is never enough"

2004 Mustang Mach1, 1970 Mustang Mach1
GT-STMC is offline   Reply With Quote
Old 03-27-2006, 02:26 PM   #6
potatoho
Cheese and Rice!
 
potatoho's Avatar
 
Joined: Aug 2004
Location: Sea-level
Oddometer: 4,683
There's some generic cable ends that kind of crimp or screw onto a bare cable, but I don't know how well they work.

Like this:


http://www.air-techinc.com/prod_cat_...=cables&ID=667
potatoho is online now   Reply With Quote
Old 03-27-2006, 03:40 PM   #7
neepuk
Such a drag...
 
neepuk's Avatar
 
Joined: Jun 2005
Location: Redstone, CO
Oddometer: 1,547
Nice fix! Can't say I'd have come up with that one.

I run an extra cable right along side the cable in use, just in case. Also I shim the clutch cable about an inch away from my bars with a zip-tie and a piece of fuel line. It really helps against breakage. I find that they break a lot more often if they don't come srtaight out of the perch for a few inches or more.
__________________
2014 KTM 150/200xc conversion 1993 BMW R100GS Paris Dakar 2001 BMW F650GS Dakar 1971 Yamaha CT-1 2007 Honda CRF150f 1977 Honda CT125 Chopper
neepuk is offline   Reply With Quote
Old 10-22-2006, 04:00 PM   #8
buffallodan
Beastly Adventurer
 
buffallodan's Avatar
 
Joined: Nov 2004
Location: Frankfort Kentucky
Oddometer: 1,707
Having recently broken a clutch cable on a T-610 (4800miles) I thought I would bump this thread for the Husky Index. The tip on using a zip tie and fuel line is a good idea.
I will be routing a spare cable so as to avoid the same hassle again... Also being a Noob I didn't know I needed to lube the slot where the cables end sits in the lever, but I do now ...also for those new Husky owners make sure you re-route the cable under the bar between the clamps if your dealer did not.


buffallodan screwed with this post 10-22-2006 at 06:18 PM Reason: Added pic
buffallodan is online now   Reply With Quote
Old 10-22-2006, 04:27 PM   #9
FBOMB
Re-noobed
 
FBOMB's Avatar
 
Joined: Oct 2005
Location: Greater Flugistan
Oddometer: 8,337
Try the motion Pro Terminator clutch cable.
I buy em here.

http://www.ktm-parts.com/Merchant2/merchant.mvc?Screen=PROD&Product_Code=K289606T&Category_Code=


They look a little more heavy duty than stock.

__________________
"Yeah, I pretty much never sit by the pool anymore." - Marco Polo
FBOMB is offline   Reply With Quote
Old 10-22-2006, 05:23 PM   #10
gaspipe
Wandering Soul
 
gaspipe's Avatar
 
Joined: Jul 2004
Location: Pickwick Lake, Tennessippi
Oddometer: 11,341
It's always best if heading into remote areas to have a spare cable zip tied in place on the existing cable. doG have mercy on those with hydraulic clutches.

Another thing to do is head down to a bicycle shop and get a generic cable and a universal end that'll work with your clutch pull on the cases. As long as you haven't wiped out the sheath around the cable (like I did recently in Mexico), the bicycle cable will get you out of a shitty situation. It packs tiny and is easy to install on the trail.

Riding without a brake is a piece of cake compared to trying to ride with no clutch.
__________________
gaspipe [the original]

Hair of the dog....
gaspipe is offline   Reply With Quote
Old 10-22-2006, 05:55 PM   #11
Loadedagain
making chips
 
Loadedagain's Avatar
 
Joined: Jan 2003
Location: West Vancouver, BC
Oddometer: 26,714
Quote:
Originally Posted by gaspipe
It's always best if heading into remote areas to have a spare cable zip tied in place on the existing cable. doG have mercy on those with hydraulic clutches.
yet another reason to keep cable clutch and ban conversion... my hydraulic exc let me down last weekend when it bled down... on the 640a i coulda just flipped to my spare cable already in place!
__________________
** iba - 22936 *** Alcan5000 - 2006, 2008, 2012, 2014 ***

Stenhouse Racing - Specializing in KTM Upgrades
custom cnc service available to suit your specific needs.
Loadedagain is offline   Reply With Quote
Reply

Share

Thread Tools Search this Thread
Search this Thread:

.
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is On

Forum Jump


Times are GMT -7.   It's 11:57 PM.


Powered by vBulletin® Version 3.8.5
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
Copyright ADVrider 2011-2014