[Danielson2881]

Hello guys,

Total newb here, so please forgive the silly questions. I recently picked up a 1973 Honda CB 350 that's in pretty good condition. For some reason though, the previous owner put some huge ape hanger type handlebars on the bike. I've got a new drag bar, but I'm left with a bunch of extra cable. The cables were in decent shape, kinda dry, but I order a new set of stock length cables anyways. Clutch, throttle, brake, and speedo.

I also ordered one of those .pdf/pirated factory service manuals off ebay, but it isn't that great.

Any tips on replacing the cables? Thanks, Daniel

 

[snorkelfork]

try following the links in the faq and download your manuals for free.

if you bought stock length cables they are still going to be too long and will require creative routing or to be shortened. do a search on this site or use google to find instructions for lubricating them

...connoisseur of slack...

 

[krapfever]

Pretty straightforward stuff replacing cables anyway. Some pointers:

1. FIRST: Look closely at where the old cables are as far as adjustment goes (maybe even mark the threads at the lock nut with a Sharpie). This will give you an IDEA of where to start when adjusting your cables. Now, loosen the lock nuts and remove the cables. DO ONE AT A TIME and note how they are routed. When you route the new cables you'll want SMOOTH curves or the cables will bind.

2. Attach and route the brake and clutch cables from the bottom up (i.e. start the front brake at the wheel and the clutch at the engine case). Once you have them in and routed (but NOT "ball parked")...remove the shouldered pivot bolt that holds the lever in place. Then hook the end of the cable in its place in the lever and rock the lever back in place. Re-install the pivot bolt and adjust.

3. Throttle: You have some work here. This cable should be installed from the Top Down. The Right controller will need to be split apart. Pay close attention to how it looks as you take out the old cable, ESPECIALLY where the old metal guide tube threads into the controller. Mark the threads where the lock nut was on the old cable and begin by threading in the new cable approximately this far. Hook the cable end into the throttle tube (the thing with the grip on it) reassemble the controller LOOSELY and slide the whole assembly on your handlebar. Again, keep it loose. Now, you'll have to remove the carbs (including the tank, crossover tube, choke "linkage" and fuel lines) to hook the cable into the throttle linkages. After noting how far the old cables were threaded into the carb linkages, remove them and thread the new cable in ABOUT 1/4" FURTHER THAN WHERE THE OLD CABLES WERE (when you adjust, you'll be working back to this point). Reinstall the carbs being careful to get that stupid choke linkage lined up and installed right. Make sure the carbs are all the way in the intake boots and vertical. Go ahead and tighten the clamps and the controller housing at the handlebars. Re-install your fuel lines and tank later.

One other thing: BE ABSOLUTELY SURE that both individual throttle cables are FIRMLY seated in the cable splitter before you start adjusting.

3. Now, do your ball park adjustments at the "bottom" end and fine tune the adjustment at the handlebars using the threaded adjusters. Throttle and clutch will be the biggest pain in the ass to adjust right the first couple of times. Brake will be easy. Speedo/Tach -- just screw 'em in.

Adjustment for the clutch and throttle is where you really need a manual or someone who has done it before with you. Just know that if you try to mimic where the old cables were, you'll be close.

Unless the previous owner was a hack.




Honda go sideways!

 

[krapfever]

Oh and yeah, you'll have to take the engine case cover off where the clutch cable attaches at the bottom end. The screws on these covers are notorious for stripping. Get a good impact driver and take your time. Invest in a set of allen bolts to replace the screws (check ebay). Seriously. Don't reinstall those junk screws.

Also, be careful when changing the cable at the bottom end linkage. There is a push rod coming out of the engine that seats in the clutch actuator. INSIDE the actuator is a small, loose ball bearing that can fall out unnoticed and piss you right the hell off when you go to adjust the clutch.

Honda go sideways!

 

[Judeyramone]

quote: INSIDE the actuator is a small, loose ball bearing that can fall out unnoticed and piss you right the hell off when you go to adjust the clutch.

Yeaah, and as soon as it falls out, it looks for the biggest heaviest thing in the garage and rolls straight under it as far and as fast as it can go.