Olde Man
Active Member
Part # 2
To go to Part # 1 follow the link below.
http://www.bigdogbiker.com/threads/clutch-cable-problems-and-solution-part-no-1.73329/
This is a continuation of a thread named Clutch Cable Problems & Fix ??? The following should help in making the spacer that goes between the cable and the clutch cable retainer. When cutting out the tab the surface should be parallel with the face of the 3/4" stock. The drilled hole will be perpendicular to the soon to be cut off face at 15 Deg.
Tang width is not critical but can not be wider than .360" because it fits into the retainer.
This is a side view showing the cut off lenght and 15 Deg angle and orientation
This shows the narrow end. So far all of the work was done on a short piece of 3/4" stock which you could put in a vice to hold. Now is the time to make the 15 Deg separation cut.
Cut this slot to allow the spacer to be slipped over the cable
File or grind the flats on the right side over the slot. This .030" min. deep flat will allow the spacer to be removed by pushing out towards the hand grip. Look in the hand control and you will see the lip on the bottom that this flat clears to allow removal.
If you look closely you will see the material removed on the top of the hole on this side and the bottom on the other side. It is necessary because the cable goes though the hole at 15 Deg and you need the clearance.
Spacer and Retainer on an old cable
Install the spacer and cable first. Do the transmission end last. it gives you more cable to work with. I pack the ball ramps and cavity solid with grease. I think this helps control the wear on the bottom end of the clutch cable.
The spacer can be installed from the front or back but the front is by far the easiest. Assemble the clutch cable and lever and install. Install the cable retainer. Slide the spacer into the hand control as shown.
Insert the coated cable though the slot as shown. Make sure that the tang is up and the slot is orientated as shown so it will slide into the retainer.
This shows the cable in final position. I am very optimistic about this "fix" from what I can see at this point. Good Luck. By the way I do not believe that the problem ever belonged to Bennett. It is a design problem. I had them very graciously fix two of my cables under warranty. I will pay for the next one.
To Go to Part # 1 follow the link below.
http://www.bigdogbiker.com/threads/clutch-cable-problems-and-solution-part-no-1.73329/
To go to Part # 1 follow the link below.
http://www.bigdogbiker.com/threads/clutch-cable-problems-and-solution-part-no-1.73329/
This is a continuation of a thread named Clutch Cable Problems & Fix ??? The following should help in making the spacer that goes between the cable and the clutch cable retainer. When cutting out the tab the surface should be parallel with the face of the 3/4" stock. The drilled hole will be perpendicular to the soon to be cut off face at 15 Deg.
Tang width is not critical but can not be wider than .360" because it fits into the retainer.
This is a side view showing the cut off lenght and 15 Deg angle and orientation
This shows the narrow end. So far all of the work was done on a short piece of 3/4" stock which you could put in a vice to hold. Now is the time to make the 15 Deg separation cut.
Cut this slot to allow the spacer to be slipped over the cable
File or grind the flats on the right side over the slot. This .030" min. deep flat will allow the spacer to be removed by pushing out towards the hand grip. Look in the hand control and you will see the lip on the bottom that this flat clears to allow removal.
If you look closely you will see the material removed on the top of the hole on this side and the bottom on the other side. It is necessary because the cable goes though the hole at 15 Deg and you need the clearance.
Spacer and Retainer on an old cable
Install the spacer and cable first. Do the transmission end last. it gives you more cable to work with. I pack the ball ramps and cavity solid with grease. I think this helps control the wear on the bottom end of the clutch cable.
The spacer can be installed from the front or back but the front is by far the easiest. Assemble the clutch cable and lever and install. Install the cable retainer. Slide the spacer into the hand control as shown.
Insert the coated cable though the slot as shown. Make sure that the tang is up and the slot is orientated as shown so it will slide into the retainer.
This shows the cable in final position. I am very optimistic about this "fix" from what I can see at this point. Good Luck. By the way I do not believe that the problem ever belonged to Bennett. It is a design problem. I had them very graciously fix two of my cables under warranty. I will pay for the next one.
To Go to Part # 1 follow the link below.
http://www.bigdogbiker.com/threads/clutch-cable-problems-and-solution-part-no-1.73329/
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