Old clutch cable doesn't fit in new perch

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10 Dec 2016 14:14 - 10 Dec 2016 14:16 #749902 by russell7
I bought a new clutch perch but the old cable is too narrow and doesn't sit flush within the perch (it looks angled in the photo). Is there a way to remedy this, do I need a new larger clutch cable and end? The new perch was from Emgo.

1980 KZ440 LTD

Trying to convert Grandpa's old bike into a cafe racer!
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Last edit: 10 Dec 2016 14:16 by russell7.

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10 Dec 2016 14:25 #749903 by KZB2 650
Replied by KZB2 650 on topic Old clutch cable doesn't fit in new perch
Is there enough slack to pull it up and on the outside of the wiring next to it....... mine is maybe off a little but not that much.

1978 KZ650 b-2
700cc Wiseco kit 10 to 1.
1980 KZ750 cam, ape springs, stock clutch/ Barnett springs.
Vance and Hines Header w/ comp baffle and Ape pods, Dyna S and green coils, copper wires.
29MM smooth bores W/ 17.5 pilots, 0-6s and 117.5 main
16/42 gearing X ring chain and alum rear JT sprocket.

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10 Dec 2016 14:55 #749905 by 650ed
Replied by 650ed on topic Old clutch cable doesn't fit in new perch
Is the adjuster (the threaded thingy) the same diameter inside as the original adjuster? In not, can you use the original adjuster in the new perch? If that's not possible maybe you could make a sleeve to take up the gap between the cable and adjuster or see if another cable has a larger diameter end. Ed

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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  • SWest
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  • 10 22 2014
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10 Dec 2016 15:40 #749907 by SWest

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11 Dec 2016 06:14 #749926 by rrsmsw9999
Replied by rrsmsw9999 on topic Old clutch cable doesn't fit in new perch
If it is only a diameter sizing issue, get a metal bushing to fit the perch and cable end. R

1980 KZ 1000E2
Crashed 6/2016

1980 KZ550A
Sold 3/2016

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  • CoreyClough
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11 Dec 2016 08:25 - 11 Dec 2016 08:39 #749935 by CoreyClough
Replied by CoreyClough on topic Old clutch cable doesn't fit in new perch
Buyer beware! Not all clutch levers and clutch perches are the same.

Most aftermarket clutch lever/perch assemblies say "fits" a certain bike, but what they really mean is they mount onto a bike's handlebars. Most handlebars are 22mm or 3/4". There is not a universal clutch lever, or perch, or cable, because all bikes do not use the same components. There are a lot of companies out there making replacement levers and perches that are not a direct factory replacement. I have seen this first hand when I use to work for a company that made cable assemblies.

Looks to me like the threaded adjuster in that picture has a larger internal pocket for your cable than what your original perch came with? There are 8mm and 9mm internal pocket adjusters, that have the same 8 mm x 1.25 threads.

This is just my opinion, and you all know what is said about opinions...

'85 GPz550(ZX550-A2)

GPz550 Base Manual --> tinyurl.com/ze5b3qo
GPz550 Supplement Manual --> tinyurl.com/h34d2o6
GPz550.com --> www.nwsca.com/scripts/gpz_forum_2005/default.asp
First Race Win GPz550 --> tinyurl.com/o5y3ftp
Last edit: 11 Dec 2016 08:39 by CoreyClough.

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11 Dec 2016 09:20 - 11 Dec 2016 14:05 #749938 by Patton
Replied by Patton on topic Old clutch cable doesn't fit in new perch
Could re-route the cable to exit straight out of -- not sideways -- from where the cable end fits into the adjuster recess.

If there's another cable length adjuster midway along the cable, might be able to also use it toward improving the cable routing.

Good Fortune! :)

1973 Z1
KZ900 LTD
Last edit: 11 Dec 2016 14:05 by Patton.

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