Experienced wrenchers, you may want to turn back now. This will be painful for you to watch... lol
I have been told this is a 30 minute repair. I'm stuck on steps one and two so it may take me days... ;)
Yesterday, my friend Iron Mike, donated to the "get hedii back on two wheels cause" by giving me a new Barnett clutch cable (thank you IM!):
First issue is taking the cable out of the top. It's stuck.
There appears to be two washers holding it tightly in place and no screw on the outside to loosen it up:
Second issue - how to reach the nut here:
(guess I may have to buy that crow's feet tool...?)
And how in the world do I get to here??? Lordohmighty! lol
I've got to laugh because I do not have anything about me that is small and dainty, let alone fingers. When I was towed last Sunday, the first thing Dale said to me when he saw me alone on the scoot was, "Thank God you're not one of those petite girls." I laughed out loud. We got the scoot up on the flatbed with me steering and walking it up then back down the ramp, no problemo.
My good friend Moon calls me one of those amazon women that he likes... I love it! :)
Now back to wrenchin' and trying to figure out this "easy" fix. Failure is NOT an option.
Edited:
Phase One - COMPLETE ~ thanks to a phone call with Stick... thank you! I found the little black E ring thing and got it off with needle nose pliers. Backed the lock nut up against the other thing and then screwed them both in to loosen the cable from the other end. Went to the other side of the bike and was able to reach in and lift it up and out. SUCCESS! ***all smiles***My son got the one screw that's stripped where the cable is attached to the frame by the little rubber clamp thing. I will need a replacement for that screw, but at least it's off.
Stick, here's the cover I am thinking you are talking about. There aren't three screws in it though... am I looking at the wrong thing? There looks like two allen wrench type things inside of the "grill" area though... do you see them?
Edit:
Ok. After removing the 'decorative' cover, three screws were found on the plate behind. Took the plate off and the gasket and found that the middle screw/nut set up was loose. Since the cable wasn't broke, there is a good chance that all that needed to be done was an adjustment on that middle screw. Oh man... if that is the case, an allen wrench and a flat head would have saved me $125 last Sunday. Now, the phase two issue is the cable. Was going to put the new one on since I do have the old one off, but there are two issues. I can't get that end part out of the lever to remove the old cable and the new cable doesn't have the same end part to fit into the lever either It will never fit (pic below). This clutch cable must not be the right one for this scoot. I have been squeezing and twisting and turning the old cable trying to get it out. Not sure if I should reuse it but that would be the cheapest fix.
So, tonight, albeit a bit disappointed that a half an hour job for all of you is going to take me days, I call uncle and will take a bit of a break to figure things out. I can't even worry about buying a new cable until I can figure out how to remove the old one from the lever anyway.
Today was a successful day. Learned how to remove the clutch cable and where it all connects. Learned a little about adjusting. And the FXE was a perfect patient, sitting there quietly with me while I learned on her. Never complained once. Just happy as could be in the garage with me. I love that about her!
She is one special ride...
p.s. I have a long history with God sending "Michaels" into my life.
They have all been a blessing to me. Originally posted in 2007:
There are many more to name in addition to all the Michaels.
You know I appreciate each and every one of you
who have been there for me these past few years.
Thank you.
5 comments:
there ya go..if your pushrod adjuster (#4) was loose............that may be your whole trouble.
follow the procedure in the manual to get that 1/2" close, then re-adjust the hand lever like it says. I'd reuse the gasket.........like I said, way simple to change if need be if it leaks after. Good luck, sweetness!
From the sounds of it, you don't need a cable. and that one with the ring lug on it is definitely not correct. To get the old cable off the lever end, you sorta push it toward the lever, and then the pivot pin will push up through the lever.
Step 1) Loosen the clutch adjuster as much as possible to get the cable as far out of the housing as you can. Look at the cable near the clutch lever (that's where they usually break), look for any broken, bent, or worn strands in the cable there and near the ferrule. If it looks good, lube the heck out of the cable and put it back together. Oh, and take that "decorative" cover off and put it on a shelf, it'll just get in the way of routine maint.
If you really need to pull the cable out of the lever, just use a small socket or open end wrench and a flat punch and gently tap the pin until it loosens up. Once it's loose, you can pull the bushings out (one top, one bottom) and then spin the pivot pin around to release the ferrule. Then the pin will slide out.
-Kuda
Thanks ya'll. It was #4 that was loose, not #5 Stick. Don't know if that makes a difference. The nut moves when the screw is twisted.
Kuda, there is nothing wrong with the cable. Still don't know why I lost all tension but will be reinstalling and going from there. Time to figure out how to adjust the clutch next.
Dale told me that he would have ridden the scoot home without a tow. He said there is an old school way to do it. Start walking/running your scoot, jump on, and go down the road without shifting. Not sure how this works without a starter. Can't kick it while its moving... at least, I can't. But I need to learn this somehow to save $$$ next time! And if all it turns out to be is adjusting #4/#5, then I know the allen wrench and screwdriver in my tool kit will solve the problem on the fly. The learning curve continues...
If #4, the nut is loose, then yes it will turn when #5, the screw is turned. 4 is a locknut to hold 5 the adjuster screw where you set it. You just have to put it all back together and readjust it. that's likely all that happened is that nut came loose, and the screw vibrated. If it was the release bearing packing it in, the nut and screw still would've been tight. I wish I lived closer, I could show you in 5 minutes how to adjust it so you'd never forget. I'm so sorry, I should have known to ASK what the original problem was before you delved into it further. Note to self..........assume nothing......I just thought you had a broken or frayed cable, since you wanted to change it
The old school way is called bump starting........you'd have to begin with the bike in neutral, (shifted with it shut off) ignition on, and push the bike like Dale said until it's going good, then jump on and kick it into gear, second is good. That gets the engine started, but you can't come to a stop without stalling it, or being able to find neutral. Not recommended for city traffic! Then just don't shift......or shift without the clutch. I've done it many times when I had to. There are also special little emergency replacement cable ends that can work to fix a broken cable until you can get a new one.
Stick
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