Any way to make a custom-length clutch cable?

ani_meher · 13th October 2017, 11:22

On my Ninja 300, I have a 1 inch handlebar riser installed, and it works perfectly for stock clutch. For the sake of it, I tried installing one more riser on top of existing. The riding position is far comfortable with the 2 inch risers, but the clutch cable gets pulled when the handle is turned to extreme right. I got the extra riser removed, but I would like to have it installed.

I think a new clutch cable with 4-5 inches more length would suit perfect for my application. I contacted Motion Pro in US who makes such custom cable. It will cost some $60, but the shipping too is $50-60! That made me think that is there any vendor in India or abroad with reasonable shipping cost who can make a good long clutch cable for Ninja 300?

Any pointers? On at least how to save on shipping!

abhishek46 · 13th October 2017, 12:11

I can suggest a cheap and interim solution.
Check how the clutch cable is routed today, and try routing it differently. You could save a few cms by re-routing it via a shorter loop.

ashwinprakas · 13th October 2017, 15:26

Spot on what Abhishek said. You not only get more usable length but the cable life also increases by a good margin.

If that doesn't cut it for you then you may opt for cables from other motorcycles, preferably from the Kawasaki stable with longer suspension travel. Reason for suggesting this is cause I own a P220 which has undergone a handle bar conversion and I was able to go for the Avenger's cable which was a direct fit. So hope you find a decent match as well.

ani_meher · 27th October 2017, 17:51

Ashwin, you were right on point. I took the bike to Kawasaki SC and asked them to fit a suitable longer clutch cable. They have used Ninja 650 cable. Now I can use two risers very comfortably, and there is no snag on the clutch either. In fact there is a good amount of free cable still remaining. Thanks for the tip.

ashwinprakas · 30th October 2017, 10:23

Quote:

Originally Posted by ani_meher

Ashwin, you were right on point. I took the bike to Kawasaki SC and asked them to fit a suitable longer clutch cable. They have used Ninja 650 cable. Now I can use two risers very comfortably, and there is no snag on the clutch either. In fact there is a good amount of free cable still remaining. Thanks for the tip.

That is indeed good news and I'm glad that worked out for you. What would we do without lean productions principles.

The upside of having extra slack is that you get better life and smooth operation feel in spite of the cable being aligned through the stays, but make sure its not touching any of the fairings cause during normal operation there's a chance for accelerated wear markers to form, not a matter of concern for me but its worth keeping in mind as anything Kawasaki doesn't come cheap.

13th October 2017, 11:22	#1
ani_meher Senior - BHPian Join Date: Oct 2008 Location: Pune Posts: 1,931 Thanked: 3,825 Times	Any way to make a custom-length clutch cable? On my Ninja 300, I have a 1 inch handlebar riser installed, and it works perfectly for stock clutch. For the sake of it, I tried installing one more riser on top of existing. The riding position is far comfortable with the 2 inch risers, but the clutch cable gets pulled when the handle is turned to extreme right. I got the extra riser removed, but I would like to have it installed. I think a new clutch cable with 4-5 inches more length would suit perfect for my application. I contacted Motion Pro in US who makes such custom cable. It will cost some $60, but the shipping too is $50-60! That made me think that is there any vendor in India or abroad with reasonable shipping cost who can make a good long clutch cable for Ninja 300? Any pointers? On at least how to save on shipping!
	() Thanks

13th October 2017, 12:11	#2
abhishek46 Senior - BHPian Join Date: Oct 2010 Location: Bangalore Posts: 1,813 Thanked: 5,864 Times	re: Any way to make a custom-length clutch cable? I can suggest a cheap and interim solution. Check how the clutch cable is routed today, and try routing it differently. You could save a few cms by re-routing it via a shorter loop.
	(5) Thanks

13th October 2017, 15:26	#3
ashwinprakas BANNED Join Date: Nov 2016 Location: Kollam Posts: 2,018 Thanked: 6,636 Times	re: Any way to make a custom-length clutch cable? Spot on what Abhishek said. You not only get more usable length but the cable life also increases by a good margin. If that doesn't cut it for you then you may opt for cables from other motorcycles, preferably from the Kawasaki stable with longer suspension travel. Reason for suggesting this is cause I own a P220 which has undergone a handle bar conversion and I was able to go for the Avenger's cable which was a direct fit. So hope you find a decent match as well.
	(4) Thanks

27th October 2017, 17:51	#4
ani_meher Senior - BHPian Join Date: Oct 2008 Location: Pune Posts: 1,931 Thanked: 3,825 Times	Re: Any way to make a custom-length clutch cable? Ashwin, you were right on point. I took the bike to Kawasaki SC and asked them to fit a suitable longer clutch cable. They have used Ninja 650 cable. Now I can use two risers very comfortably, and there is no snag on the clutch either. In fact there is a good amount of free cable still remaining. Thanks for the tip.
	(2) Thanks