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Old 08-22-2008, 11:05 AM   #1
oolai
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Default Repairing clutch cable on Ninja 250

hi all, thanks for checking this out.

I'm not very knowledgable on motorcycle repair and I had an accident a couple weeks ago and on the way home the clutch cable broke. I've gotten the part number and I'm going to go look for a store that sells it this morning. I was just looking for some insight on how hard it'll be to replace by myself. It broke up near the handle. I can take some pictures if anyone wants me to, thanks in advance for any advice.
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Old 08-22-2008, 11:14 AM   #2
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after checking it out the cable runs through a sleeve from the middle right side of the bike up to the clutch. theres a nub on the bottom end thats too large to go through the sleeve and it might be the same case on the top end, I haven't figured out how to release the cable from the handle. do i just slide the cable up through the sleeve then crimp the nubs on to the ends after the cables in place? any help is appreciated.
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Old 08-22-2008, 11:26 AM   #3
cbdallas
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1) Use the adjusting screw on the bottom of the cable (the end attached to the engine) to give you as much slack in the cable as possible.

2) Adjust the clutch lever (on the handlebar) adjuster screw all the way in, also to give you as much slack as possible. Make sure the slot in the adjusting screw and the locknut are aligned with the slot in the clutch handle so the cable can be slid through it during removal and installation.

3) Remove the cable from the clutch lever on the engine end. This might require pliers to hold the cable while you maneuver it out of the slot it rests in in the lever.

4) Now that you have all that slack, remove the cable from the clutch lever on the handlebar.

Paying close attention to how the cable is routed through the engine compartment, remove the entire cable...casing and all.

Install new cable in the reverse order of the way you removed the broken one.

Be careful on the handlebar clutch lever side not to get the cable crimped inside the adjuster screw once you've installed it inside the handle. I had to use a flat screwdriver to push against the cable while turning the adjusting screw so the cable would remain fed correctly until I turned the adjuster screw slot toward the rear of the bike.

Adjust cable as necessary at the engine side, and then use the handlebar adjuster screw to make fine adjustments. Make sure to leave 2-3 mm of freeplay in the handlebar clutch lever so your clutch fully engages.

Sorry if this doesn't help you much. It's an easy operation, just kinda hard to put into words.

Last edited by cbdallas; 08-22-2008 at 11:41 AM..
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Old 08-22-2008, 12:01 PM   #4
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Ok thanks!

I don't think it'll be that hard to remove the cable, it snapped up near the handle. when I buy the new cable does it come with the large rubber sleeve that the cable is cased in? that would make things a bit easier as long as it's not too hard to feed the cable through the middle of the bike.
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