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D7 clutch cable fitment
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shopguy
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December 2, 2019 - 10:38 pm
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Can someone give me the short and sweet on setting up a new clutch cable on the D7?

Engine is all rebuilt.  I bought a new cable.  adjuster at engine is nearly completely backed out.

I fitted the barrel into the clutch arm by the sprocket, but as I pull the barrel into the lever....I run out of free play, as if the inner cable is 1" too short.

The only thing different that stock is I'm using clamp on levers.....not the welded purchase ones.

thanks

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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Mick W
Chester/ North Wales Flintshire Border
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December 2, 2019 - 10:57 pm
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That is the problem shopguy. The cable is too short with adjusters. Look at some of these posts ** Please log in to view **

Mick

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shopguy
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December 3, 2019 - 1:28 am
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Thanks Mick.  I thought I was losing my mind.  I'll just have to shorten the outer.....     nothin's eezy.....

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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cocorico
Central France
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December 3, 2019 - 7:43 am
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That problem is not unique to Bantams, either. As long as you have enough slack in the length of the outer it's fairly easy to shorten it (I use a Dremel-type tool with a cut-off disc). An alternative (especially if the whole cable is too short) is to learn how to make your own. It's not expensive, not too difficult and there are plenty of guides available on-line. Its also useful if you get other old bikes...

1956 D3 running, lights to sort. 7 other bikes in the Barn, including a Morini 250 now insured and on road testing.

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sunny
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December 3, 2019 - 8:48 am
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all cables  tened   to  look     &   feel   short  wen  fitting    dont    cut  them   till  youv     checked   the  lenth   ,   this  is  also   the  time  to  fit   oilseal   P N / 132

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shopguy
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December 4, 2019 - 2:55 pm
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I will modify the cable or make a new one as needed.   I've made cables, its just frustrating to find that when I buy one to save time.....I wind up having to "fix" he new one anyway!  

Thats said;  with a new clutch pack - how many threads should be exposed on the adjuster screw, from the lock nut face?   Seems that its "fluid" as to where the adjust should be.  How about the lever arm position with respect to the housing?  just past 90 degrees from the cable "line"?

Where I set the arm makes a HUGE difference in how much adjuster screw is exposed.

Shopguy

Mike the Shopguy.  Head muckety-muck of FBM Engineering; making rolling oddities and noise generators from otherwise normal stuff

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sunny
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December 4, 2019 - 3:43 pm
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the  cable  itself    dos not  have   ajustment       ,,the  only  clutch ajustment     is  the  grubscew and  lock  nut   on  the  levers   center     IF   you   put    the   lever  and  its   BUSH   P N / 184     it  has  to  come  OUT   AND   fited  correctly       ,,the   ballbaring    MUST  be  fited  insde  the  lever  unit    NOT    between   the   TWO   push rods    

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cocorico
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December 4, 2019 - 4:44 pm
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Unfortunately, buying replacement cables is not guaranteed to give you what you want unless you have a bike exactly as supplied new - and even then you may still not be lucky unless the supplier is involved in the make, not on the make! It's easier if you have the old cable available to measure what length you need, so you can specify that to the supplier.

1956 D3 running, lights to sort. 7 other bikes in the Barn, including a Morini 250 now insured and on road testing.

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mike p5xbx
E-Sussex
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December 4, 2019 - 4:59 pm
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The way I do it
wind the adjuster screw all the way out and fit cable to engine and handlebar leaver
put your finger under the engine on the leaver arm and make sure it has free some play pulling against its return spring
(this is in case the cable has the wrong length inner you would not feel any free play)
then screw the adjuster screw in until you can feel just a small amount free movement at the engine leaver NOT the handle bar leaver
then lock the screw in place with the locknut

D? - D10- D14 Bantams 350 AJS -500 Triumph http://bsanotru.....lfire.com/

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