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‘81 aftermarket clutch perch width

Discussion in 'The Garage' started by Blair_repair, Oct 15, 2020.

  1. Blair_repair

    Blair_repair XS650 New Member

    4571445A-B929-41F3-9114-5D0701ED83D1.jpeg 1FE9B4A7-0737-48CD-A347-0C93A4DFF315.jpeg
    I have an ‘81 and my clutch cable snapped. The OEM perch and lever has the place for the mirror which I don’t use so I wanted to switch to a perch with no mirror. Ordered one off mikes and the portion of the perch which the adjuster threads through is about half the length of OEM perch. This creates excess free play in the cable that free play adjuster has a hard time compensating for. In the photo, mounted perch is OEM. I know of the method of cutting the barrel off the cable a drilling a hole in it and soldering it at the desired length but I’d rather avoid that. I don’t believe I can make any adjustment in the case where the cable adjusts to either. Does anyone know of a different model bike with a perch that is the exact width to the OEM XS. Or of an aftermarket perch? Or of an extended cable free play adjuster that can compensate? 4571445A-B929-41F3-9114-5D0701ED83D1.jpeg 1FE9B4A7-0737-48CD-A347-0C93A4DFF315.jpeg
     
  2. xjwmx

    xjwmx It's just the unknown. Top Contributor

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    Best bet might be to actually shorten the cable a bit? You can buy barrels that have a set screw but for something permanent I'd probably hit it with the Zeus machine[/QUOTE]
     
    Last edited: Oct 15, 2020
  3. 5twins

    5twins XS650 Guru Top Contributor

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    I had the same issue when fitting a Kawasaki lever and perch .....

    [​IMG]

    My solution was to fashion a shim to place on the cable down where it enters the side cover .....

    [​IMG]

    I made the shim by cutting the top off of an old cable elbow .....

    [​IMG]

    [​IMG]

    [​IMG]
     
    TwoManyXS1Bs likes this.
  4. xjwmx

    xjwmx It's just the unknown. Top Contributor

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    I would still modify the cable, but I think you might find a good piece to make a shim with in the roll pins box at the hardware store. Squeeze it closed slightly to keep the wire inside
     

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  5. 5twins

    5twins XS650 Guru Top Contributor

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    That won't support the cable sheath. You need a "big" end on the shim for the cable sheath to fit into.
     
  6. Blair_repair

    Blair_repair XS650 New Member

    Sweet! That seems like it should be easy enough to do. Don’t even have to buy anything, just chop up the old elbow! Thanks!
     
  7. 5twins

    5twins XS650 Guru Top Contributor

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    As you can see in the pics above, I initially cut the spacer a bit long. Then I shortened the small end up so it would fully seat into the existing cable elbow .....

    [​IMG]
     
  8. bosco659

    bosco659 XS650 Addict XS650.com Supporter

    Maybe slide a larger roll pin over the smaller one, aligning the splits? Trim to length? The one you made is really nice but not everyone would have a spare elbow to sacrifice
     
  9. xjwmx

    xjwmx It's just the unknown. Top Contributor

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    Not supporting the cable is a good catch. However I wonder if there's not enough room for the roll pin inside the cover. That would be the best place to take up the slack really. Then somebody can ask...why didn't he shorten the cable :)
     
  10. GLJ

    GLJ Never go faster than your guardian angle can fly. Top Contributor

    Jim likes this.

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