Clutch cable for my traveller

[Namikuz]

So on the last little jaunt I went on, my clutch cable end pulled out leaving me sans clutch....... I found a direct replacement for $19.88 at an aftermarket parts supply house. MP 03-170 for an 1987-2009 Kawisaki EX500/500 Ninja. Went straight on as made for it!!! The only OEM I found is in the U.K. at Grahms and it's $47.00 plus shipping.... I went with the Kawi part....... I read in someone's post on this site that an upper/lever side needed an adaptor for the Kawi part.....? works out of the box for mine. Traveller is TRAVELLING!!!!!!!!!!!!!!!

[edfmaniac]

I discovered that as well. Buy another one for a backup because mine didn't last but about a year. I was putting 10,000 miles a year on it then though. Yours might last longer.

[Namikuz]

I discovered that as well. Buy another one for a backup because mine didn't last but about a year. I was putting 10,000 miles a year on it then though. Yours might last longer.

10K a year is commendable!!!! I do MAYBE 6k per. But I don't ride below 30 degrees anymore, so that cuts my season down in the Utah mountains substantionally (snowing today!!!),now in San Diego, 15 - 20k per was NO problem, lived on my bikes.
So, own stock in a rurber plant to keep the hungry little beasts in tires?????? hehe. My Suzi 1100 goes through tires like water..... no my riding style of full bore and my hair on fire has NOTHING to do with that , I'm sure.....maybe......possibly.... COMPLETLY!!!!!

[DAVID THOMPSON]

looked up the motion pro site and found this listing
maybe a zero missing in the number above in the original
post
EX 500A 0500 Std 1987 - 1993 03-0170
EX 500D 0500 Std 1994 - 2003 03-0170
EX 500D 0500 Std 2004 03-0170

dave

[Namikuz]

YUP!!!!!!!! "0170" is correct.... thks, didn't notice I did that. Send'em to collage, buy'em books, teach'em to proof their work...and they STILL mess it up!

[DAVID THOMPSON]

and they STILL mess it up!

the only time you really mess up is when you fall OFF
and the only time your in trouble is when the wife and your girl friend get along with each other.!
dave

[Namikuz]

and they STILL mess it up!

and the only time your in trouble is when the wife and your girl friend get along with each other.!
dave

Well................. For me my wife of 28 years "IS" my girl friend!!!!!!!!!!!!!!!!!! So I can live forever... I don't fancy dieing in my sleep an HORRIBLE death and disMEMBERment!!! if ya know what I mean......

[radiograf]

Can I recommend that you apply chain lube to the point where the cable enters the lever. If this seizes the cable will flex and work harden, eventually causing it to snap. I use chain lube as it sprays on thin and then thickens, so it enters the joints easily. Its also fairly waterproof

[DAVID THOMPSON]

the end on the cable on all my mz bikes is a problem
it does not mate well with the lever
the one on the rotax powered bike operates under way tooo much pressure
i have broken more cable ends off on it than any other bike i have owned
dave

[Namikuz]

Can I recommend that you apply chain lube to the point where the cable enters the lever. If this seizes the cable will flex and work harden, eventually causing it to snap. I use chain lube as it sprays on thin and then thickens, so it enters the joints easily. Its also fairly waterproof

Mine was going sloooowly. I had to keep adjusting the slack. The end finally just pulled out cleanly. It was not stiff, binding or anything unsusal other than needing frequent adjustment.

[billr]

Can I recommend that you apply chain lube to the point where the cable enters the lever. If this seizes the cable will flex and work harden, eventually causing it to snap. I use chain lube as it sprays on thin and then thickens, so it enters the joints easily. Its also fairly waterproof

I second this one...
When the end snapped off my clutch cable, took it down to a local shop that built up a new one.
The guy that did it said, "Make sure and keep some grease on the lever end. Keeps if from binding and making this happen again".
When he said that, I remembered thinking the clutch seemed to be "creaking" at times, just before it let go. Lubed the cable, but didn't think about the ends.
Needless to say, it gets a "grease check" at least once a month...
YMMV,
Bill R