DR650 Replace Clutch Cable

[@byroncrump4390]

My old mans enduro racing set up tip was to tape a spare clutch cable along side the newly installed one so there’s zero install time especially while you’ve got tank off anyhow.

[@BikerBytes]

Pro tip, tie a piece of string to one end of the cable. As you pull the cable out the string will trace the route which you can then use as a guide when installing the new cable 👍 Bet that clutch feels awesome now 💪

[@BikerBits]

Bloody Ripper idea! Will have to remember that one 👍

[@wobblysauce]

This...

[@Zinisster]

@@BikerBits Love the vids mate. You have been asked this a million times probably Those racks either side on Max. The reason is , I’ve just bought a DR 650 and it’s going to get dirty.

[@MVDBR]

Got to love a biker bits bonus vid! Thanks Mark 👍

[@azlong4596]

Mark if you regularly clean and lube all pivot points where the cable moves and clean and lube the cable you will maintain the fluid movement of the cable . Your original cable did not need replacing just some standard maintenance. You said you have a cable oiler so use it, run WD40 down the cable first to clean out water and debris build up then finish with cable lube shot through the same cable lubber and your done. Some times you make me cringe buddy but I still love the channel, keep on keepin on.

[@revbharvey5046]

Thanks Mark. I really enjoy watching some of this kind of maintenance and repair. It doesn't look so intimidating when you watch someone else have a go. Cheers.

[@MickOTooleroadglide]

G’day Mark & Nay awesome shed bike mechanic maintenance you definitely can’t beat tinkering around & getting to know your own bike it sure does help when your out in the middle of nowhere to have some ideas of what make it tick, great 👍 job on the clutch cable & thanks for MCT this week, cheers Mick 👍👍😎

[@jimmybutler6451]

Not enough people do their own work on their bikes, cars etc. Awesome job and tutorial Mark thanks.👍

[@chuddledollops]

Great vid, you can replace that clutch release arm with the slightly longer DRZ400 one and it makes the clutch lighter too!

[@CamperKev]

I love the DR650 for a number of reasons, but I can't understand why companies like Suzuki and even Yamaha with their expensive T700, still use clutch cables instead of hydraulic clutches. It's 2021. They need to get with the times. Even my 2010 Husqvarna TE510.has a hydraulic clutch and they date way back further than that. I have broken a few clutch cables in my time, Mostly on bikes in the 80's and 90's but I have never had a problem with a hydraulic clutch. Apart from the exceptional reliability, hydraulic clutches never need adjusting and they feel so much smoother to operate. I guess I'm more likely to accept a clutch cable on an old school DR650, but the Yamaha T700 is out of the question. Anyway, that's enough of that. As always, I love your videos Mark. Thanks for another excellent upload. 👍🏼😁

[@jamesbh101]

Here here. I put one on my Vulcan 900 and I love it. I was toying with trying to fit one to the DR but I don't have the time.

[@olivers.7964]

Good video. When you thread the end of the cable back into the clutch lever, hold it in its original position and do not turn it 180 degrees to insert the end of the cable. If you then turn the clutch lever by 180 again, the cable is also "twisted" by half a turn and it no longer runs optimally through the guide channel...

[@adventurehwyhubhwy5817]

Good effort Mark, I just replaced my clutch cable and installed a heavy duty Barrett clutch plates, pressure plate and springs and the clutch is now working fantastic. Really enjoy watching you giving the mechanial ventures a good go. You may sometimes go about it a funny way but the end result is the same as if you paid a workshop a pile of dosh. Well done Mark. 👍👍HWY

[@FULLPELTAdventures]

Hi HWY, with the heavy duty plates, is the clutch feel still really light and easy? Regards Pete.

[@magnusconsul]

thanks Mark, its great to watch some one at home doing a little bike maintenance we can all learn.....KOR....

[@oyleyhands1332]

As I just noticed someone else suggesteed, I was going to suggest cleaning up the old one and if ok lay it adjacent the new cable, so no need to take stuff apart to fit if the new one fails on a ride.Dry lube such as PTFE spray ( Teflon) works on cables and does not attract dust like a wet lube. Tape up the ends of the spare (old ) cable.

[@tjracingteam]

I try to give the clutch cable a spray through with INOX from time to time. I've found water and corrosion is the biggest issue I've had. I use a handy little cable lube attachment which makes the job very easy. Dont forget your thottle cables. They may be in the same condition. My son had his decomp cable break recently with a two week wait for a replacement. It was brown and rusty where it broke. Decomp cable is probably one of those things that get neglected.

[@lindsaymillard2881]

Don't forget to put a bit of grease on the end of the cables that sits in the levers. Reduces wear and tear.

[@MOTODANS]

Nice one Mark, I agree don't lube the cables attracts the dirt can't argue with a $40 cable every 12 years!

[@dalebrooks405]

Use teflon spray on the cable its dry and slick but does not attract dirt or grime Been using it for years works great

[@wixee123]

Diesel bath for a few days should sort that old cable out.. Top job as usual..!! 👍

[@Sum4Seb]

Good job, the feeling of a new cable is amazing! Crazy what you get used to... *T4S* 😀👍🍻

[@AfricaTwin-Stuff]

Good exercise and one the many of us ignore but shouldn’t.

[@gsamanyika75]

Good job mark best thing for cables is cooper slip or fit a new one

[@utbelegs]

Ordered the OE Suzuki cable..it was pre-lubed from the factory..very slick.

[@FULLPELTAdventures]

it surprises me that the DR650 does not have rubber dust covers on the cables at the levers. Great Vid Mark.

[@tjracingteam]

MY XR650 doesnt have them either Pete ? Cost/weight?

[@FULLPELTAdventures]

@@tjracingteam The T700 doesn't either, Bazaar.

[@tjracingteam]

@@FULLPELTAdventures Maybe it's a condensation thing Pete?. I'm guessing if it was semi sealed with a rubber boot it may hold water/moisture etc it would never dry out?.

[@FULLPELTAdventures]

@@tjracingteam you maybe right.

[@paulbourgoin2436]

Thought you were going to stab yourself prying that cable off!! LOL ... You know when you need to clean some tight spaces on the bike, especially if it's really greased up, I use an old toothbrush. Small, does not scratch and does the job. And hey recycling is a good thing. Great vid Mark!

[@paulwood7798]

With the various teams I have worked for down the years all have said the same. Do not put oil or grease anywhere on the clutch cable no matter what the manual says. WD 40 from the top while working the cable depending on bike accessibility. Sand is worse than grease or oil and will gunk up the cable in double quick time and add in dust and rain it will quickly gunk up. Just for piece of mind Mark on older bikes at least a couple of times a year just spend 5 mins WD 40 ing it. Can't believe being that stiff the old cable did not fail after all this time.

[@paulwood7798]

I should also say we never used chain lube on chains either terrible stuff. Light Gear Oil for that and quite a lot of specifically made lubricants are actually designed to make you keep using them and buying them rather than being beneficial to the bike. It's like many of the riders we have seen down the years whose leathers drinks bottles and bikes come emblazoned in the latest and greatest energy drink logo when really inside the bottle is cordial cold or ice teas or plain water.

[@whatsstefon]

@@paulwood7798 those drinks taste like cough syrup made from an elephants sweaty balls. As for chain lube, most manuals even state to use heavy gear oil, not chain lube.

[@kannermw]

If the dirt can get inside the cable with lube it can certainly get in without. Once inside the sheath this dirt is abrasive and will more quickly wear out cable and/or sheath than if there was lube. The best solution is to use brake cleaner to periodically flush out old lube if it hasn't been done in awhile and then use a PTFE based lubricant. The frequency for this all depends on riding conditions. The same can be said for chains. Use PTFE lubricants and it will dramatically increase chain life by encapsulating and removing the trapped dirt particles so they dont destroy the seals and also increase roller/sprocket life. For most street riding this method will mean you will likely never need to clean the chain. This will also provide maximum life without the horrible mess of chain oilers or simular chain oil lubricants and time consuming rim and bike cleaning. For off-road riding the dry lube will not attract excessive dirt which is just the problem you want to avoid.

[@paulwood7798]

@@whatsstefon they do indeed but I reckon one in twenty riders I know ever read a manual and I have been involved in the motorcycle industry thirty years.

[@Arachnoid_of_the_underverse]

@@whatsstefon 90w gear oil is good because it has less fling capability than lighter chain oils

[@haliburtonadventure5531]

Great vid thanks! Going to do my DRZ400S this spring.... I assume it's very similar to the DR650

[@billcotton1551]

I would bet you are right that the oil in the cable attracts dirt , when you do a lot of off roading like you do.

[@PotterOnTheWater]

Hey Mark - had a similar issue with one of my throttle cables (Virago 250) recently. It was binding - I tried oiling it up thinking it was just gunked up but no luck. It turned out the cable was frayed inside the plastic and the frayed bits were jamming inside the sheathing. Replaced it and now the throttle opens smoothly and closes itself easily by the return spring as it should. Kelly

[@brucefleming1743]

Good stuff Mark 👍🇦🇺

[@metaldog7128]

Well done…mark we live and learn 😁👍 or test and try 🤪

[@motorcyclequests5358]

Good video this should come in handy

[@NZBallBag]

Tie a piece of string to tje cable before you pull it out then attach string to new cable and use as a guide

[@danielnz6925]

Now I know what to do..👍👍

[@wobblysauce]

11:25 look at the other side of the cable, that is most likely the point rubbing. As you said you change the oil and clean the air filter, but this should be checked at the same time. only takes a min or two.

[@marty4933]

It is very hard not to lube up cables on a bike. Just a built in desire.

[@freyja4954]

I used graphite base dry lube. So for one it doesn't collect garbage 2 it gives that little bit extra protection.

[@mmaaddict78]

Does the graphite build up and ever need cleaned out? I was thinking about trying some on my Kawasaki clutch.

[@freyja4954]

@@mmaaddict78 It does build-up over years. but by the time you generally have to clean it out maybe about the same time you would replace the cable if you didn't use it. Usually I can just blast it with some carb or break cleaner and reapply and it's good as new.

[@blakedowson2833]

Good vid very useful yer i never oil the cable

[@davidhanger5795]

Where did you get the mounts for the auxiliary lights on the Barkbusters?

[@BikerBits]

I made them! :-)

[@davidhanger5795]

@@BikerBits that's what I thought. Good job on those!

[@jesse6460]

🤙

[@JCKloppers]

Lube it with graphite powder - dry lube

[@luksluks100]

Good job

[@BikerBytes]

Damn

[@motorcyclequests5358]

I think I new someone in the navy that had weeping petcock

[@doniturner5077]

Kool bananas 🍌 sir.

[@zzxx33mh]

🤙👌

[@Dastardly_X]

🤘🏻 🌟 🤘

[@thegunnut221]

You just had to lube the old cable.

[@crewzincool]

Cut that old cable up and let's look where the wear is in it.

[@smrangers22]

OMG ha ha . you have got to be joking ha ha all that crap just to change a clutch cable !!!! jesus this is a joke ? yes . please tell me this is a joke . . my 2003 bmw f650 gs takes 2min change the clutch cable . ha ha ha ha ha i cant stop laughing !!!! hello from scotland , the english took less time to invade us ! ha ha ha

[@BikerBits]

No Joke :-)