Clutch & Throttle Cables. August 2006

Some riders are also put off by the perceived awkwardness of accessing the cables and lubricating them. But as the CDR Nokia Yamaha team mechanics will show, it's neither daunting nor difficult. All you need are a few basic tools and the step-by-step handy tips in this issue's CDR Tech Talk.

1. Starting with the clutch cable, work from the gearbox end first, loosen the cable freeplay nut (inset). This will allow for more slack in the cable making it easier to release it from the lever end.

2. Undo the clutch adjuster (circled) so the slot lines up with the corresponding slot on the clutch perch (inset). Dirt build up here can effect the amount of play in the clutch, so wipe this area clean.

3. The rubber shrouds on most clutch perches are designed to keep mud out, but they can also allow dust, dirt & water in. Peel back the cover and wipe away any excess dirt.

4. With the rubber shroud peeled back, undo the clutch lever bolt (inset) and remove the lever. Check the cable for any loose strands and replace the whole cable if any fraying is present.

5. Using a cable lubricator (inset) makes lubing easier as it forces lubricant between the inner & outer cables. Spray with a dedicated cable lubricant like YAMALUBE Performance Cable Lubricant.

6. Ideally, you should leave the lubricant to soak in and work its way down the length of the cable until you can see it seep out the bottom end before re-attaching the cable to the lever and adjuster, which is the reverse of steps 2 to 4.

7. The throttle cable is a little bit trickier to access, so take extra care when separating the two ends of the throttle cable from its housing. Peel back the rubber shroud as per the clutch cable.

8. Remove the screw holding the throttle cable guides in place (inset). The two halves should break away as shown.

9. Remove the cable ends from the throttle tube (inset). This will be easy as the throttle cable doesn't have the same tension as the clutch cable. Slide the throttle tube off the handlebar.

10. The throttle tube can collect dirt and wear prematurely with the constant friction from twisting the throttle. Wipe clean and spray with a lubricant like YAMALUBE LubezAll Multi-Purpose Lubricant.

11. Don't have a cable lubricator? As Dave demonstrates, a plastic bag with a hole in it, cable-tied to the throttle cables (inset) can work just as well. Apply a good amount of YAMALUBE Performance Cable Lubricant and let it drain through the length of both cables.

12. Re-attach the throttle tube to the handlebar. Apply a small amount of YAMALUBE LubezAll to the throttle cable guides before reconnecting the cables. This will help prevent cable wear & fraying. Reattach the guide screw (inset), and rubber shroud. Check for free play and free action in both clutch & throttle levers before you start your bike - this is ESSENTIAL - free play means you're free to play!