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Discussion Starter #1
Hey guys, dropped my bike and broke my bars last week. Went to put the stock bars back on but I'm stuck on what to do here. The cable won't slide back in the little sleeve that holds it in place to raise/lower the tension. I tried prying it open a bit but it's thick metal and I'd have to put more force than willing with it connected to the carb. Any suggestions?
 

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FREEBIRDS MC CENTRAL NY
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16,076 Posts
take the nut off the end and slide it in,then tighten nut back down.no need to space it out that way

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FREEBIRDS MC CENTRAL NY
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pull up on the linkage that the cable end goes into to give yourself some play

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FREEBIRDS MC CENTRAL NY
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ok looked at first and second pics again.place a large screwdriver in between the opening and pry a little. just go slow and steady

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Discussion Starter #7
I've been trying to pry it open for a solid hour, pliers, screw driver everything that would fit and give me leverage haha but with it attached to the carb I'm scared I'll break something with too much pressure. Was thinking find the right drill bit and bore it since it only needs the slightest more room and seems like the only option other than heating the metal to bend it... But then I'll have to drain the full tank I currently have
 

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How did it come off in the first place? Are you saying you put the stock bars back on and removed a shorter/longer cable, and you're trying to put the stock cable back on?
I don't understand if why it came off at the carb to begin with. I would guess a round file or a drill bit would work, just don't understand why it's suddenly "too small" now....
 

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Discussion Starter #9
No idea how it came off, I'm guessing it happened when the previous owner put the other bars on( taller z bars)and I just never noticed?
 

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Discussion Starter #10
Well, was able to get the piece bent out enough and everything is good... Except now my clutch lever is insanely stiff! I sprayed wd40 on the cable at both ends but still really stiff, any ideas? I used to barley have to pull on it. Also seems like I have to have it open more now, previously it would engage when barley letting off the clutch now it's super stiff and I almost have to let off the lever completely before it engages
 

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FREEBIRDS MC CENTRAL NY
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first off,wd40 shouldn't be used for cable lubing. get a good lithium based cable/chain lube.do you still have the z bars on the bike?sounds like the cable may be a little too short and is now binding.did it work fine before?

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Sounds like the adjustment might be off on the clutch, but for the stiffness, maybe unhook one end and see if the cable is binding. Look for any sharp bends or kinks in the cable.

The throttle cables in your first pics are supposed to thread though that bracket instead of slipping through, that's where the adjustment is. You're supposed to crank them in/out with a wrench. Also, the cables aren't close to equal in adjustment, which might be a problem unless one cable is stretched more than the other.
 

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first off,wd40 shouldn't be used for cable lubing. get a good lithium based cable/chain lube.do you still have the z bars on the bike?sounds like the cable may be a little too short and is now binding.did it work fine before?

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Yup! WD is water based. It can free things up, but they usually go back to sticky and squeaky in no time.
 
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