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Re: Broken manual clutch cable
You can go to www.Searspartsdirect.com and put you units model number in and order the cable yourself. They can ship it right to your house and you can swap the cable yourself with just simple hand tools.
You can see the details on the idler attachment in the parts schematic when you are ordering your new cable.
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It sounds to me like the inside of the clutch cable itself has broken strands that is making in bind up. Disconnect the cable at the motor (transmission) now see how difficult it is to squeeze the clutch lever on the handle bar. If it is easy to pull back and forth than the clutch cable needs replacing.
see this steps and fix it. God bless you Clutch Cable Replacement
The clutch cable provides a means to "break the drive" between
the engine and the wheels. The engine spins constantly, but the wheels
do not, so in order to stop a car's wheels without turning off the
engine, the wheels have to disconnect from the engine. When the clutch
pedal is pressed, the cable disengages the plates, allowing the driver
to shift gears or coast without killing the engine.
A failing clutch cable may make the clutch pedal difficult to
depress. If the clutch cable fails, the clutch pedal may remain on the
floor and not return to its normal position.
To replace the clutch cable, disconnect it from the clutch pedal
(usually inside the vehicle) and from the release mechanism or cable
attachment that operates the clutch assembly (usually at the
transmission beneath the vehicle). A new clutch cable is then installed
and adjusted. (The specifics vary according to the vehicle and range
from straightforward to very difficult.)
cable broken or lever? if its the lever just replace it shouldnt cost too much.... if its the cable also replace this is slightly more difficult then the lever though.... both are possible to do yourself depending on how mechanocally minded you are... hope this helps
Well, you only need the clutch to release, and that cannot be major. Inspect the cable completely, does it move at the trans end when you pulll it. What is inside is essentially a fork on a release bearing, a rod, and the clutch spring plate.
There are 2 types of cable used. Auto Adjust...and Manual Adjust.
Either are easy to fit. Remove tray over foot=pedals will allow you to
access one end of the cable. Here the cable simply hooks over the pedal
linkage. Remove the outside plastic panel in front of windscreen to
allow the cable to be installed. If the cable is the Manual Adjust
type, loosen off the adjuster nuts at the clutch lever on the front /
side of the gearbox and pull out cable.
If car is fitted with Auto Adjust cable...A Plastic Retainer Strap will
be installed on the cable at the gearbox end. This retainer should be
latched into place before removal. If the cable is broken at present
you need not bother with this retainer. A new cable comes with this
retainer already fitted. Its simply a matter of fitting the cable in
place at both ends and then releasing this retainer. Do NOT release
this until the cable is fully installed at BOTH ends
Sure you can fix it yourself. First lets make sure the cable is broke. When you pull in the clutch does the other end of the cable move?
If not then disconnect the cable from the lever and pull on the end by hand. Did you just pull a broken cable out of the sleeve?
If so then purchase a new cable and replce the broken one paying particular attention to the way it is routed. place the adjuster on the lever end a tad less than half way. Adjust the clutch end of the cable to take up the slack. Work the lever 3 times ( to seat everything) and use the adjuster at the lever for final adjustment. You want about 1/4 to 1/2 inch of play at the end of the lever befor the cable starts to actuate the clutch arm. Adjust and lock.
On your bike there are two clutch parts that can wear and cause this problem. The broken spring should be replaced but is not causing the problem. Check the bottom of the clutch release shaft #13102. The end of the shaft may be broken, bent or severely worn. The part the shaft engages with is the clutch rod #46102. It could be bent, broken or severely worn. This part is inside the clutch hub. Just remove the five springs and then the outer cover plate and the rod should be accessible.