Trying to replace my clutch cable. Got the old one out all the way, can't get the new one to lock into the threads on the transmission cover.

I also can't get the old one to screw back in again either, so I'm wondering if there's a trick to it that I'm not getting right?

Transmission cover is all the way off the bike. Thanks.

 

Check to see that the threads in the cover are not stripped. It's soft aluminum, see it happen once or twice.

 

 

It's an alignment issue, I assure you. It don't go straight in perpendicular like you'd think, and the threads are fine so that's against you also.

Look at it from the vantage point from the gasket side and visualize a straight line where the cable shoots thru, that may help.

 

It can be a pain in the ***. I used a tap and die set for the cover's threads, hung the cable from the ceiling, then the cable end screwed right in, walla.

 

I just went through this a few weeks ago changing my silver cover to a black cover....I had to go to a tool store an get a thread chaser to run through it then it spun right in.

 

This was definitely the solution. I must've tried 50 times with the cable hanging from the ceiling. Wouldn't grab the threads no matter what angle I went in at.

Grabbed a tap & die set at O'Reilly's 5 minutes before they were closing, turned the tap through the cover and then it went in first try.

Thanks for the advice!

 

Becareful using a tap as you may open the threads enough to weep trans oil.

Maybe use a "bottoming" tap and go the first 3-4 threads...

OP~ while you're there, you might as well install a Burley EZ boy clutch device. Reduces lever effort 40% but has the same lockup as before.
People are impressed how well they work, myself included. (I've put them on a few Evo's and Twinkies, over the years)

 

Rotate the cover not the cable to thread it in.