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Clutch and exhaust lifter

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Took my pride and joy for a run from Cornwall to Bournemouth yesterday (via Windmill Garage, Honiton - E0!). Got as far as Bridport and was hit by a double whammy. The nipple (I found) had pulled out of the exhaust lifter cable at the lever end and the clutch retaining nut worked looses so no clutch. This was at 6.45pm. I was delivered home by Green Flag at 2.00am the next morning. So - two questions. What is the correct route/length for the exhaust lifter cable. Mine has always been very, very stiff to lift. And two, what holds the clutch retaining nut tight? Should there be a spring washer behind it (55 ES2). What torque setting should I use? I can't find it on the spare part plates. Any help very much appreciated. BTW the guys at the Windmill Garage were brilliant as I attempted a roadside repair there. It got me as far as Bridport! George
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I should have added - is there a special tool (C - spanner?) for holding the clutch body whilst tightening the retaining nut? I can't find one at the usual sources. Cheers George
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Yes, there should be a large spring washer behind the nut. As for tightening, I put it in top gear and press hard on the rear brake lever. John

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Bummer! I've just out it back together (no spring washer) after de-greasing/cleaning and the use of Loctite. I don't think there ever was a spring washer there but I've found an old parts list which shows part no.A2/373 (pic N3) so I'll have to try and source one. Very much appreciate your reply, John.
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Thanks Baz. I'll have a squint at that in the morning. It has been terribly hard to lift with the lever - hence the nipple pulling off. I just wondered if there was a "standard" routing for the cable. From memory mine heads towards the rear from the actual lifter, does a hairpin loop still under the tank and out at the front of the tank up to the left hand bar. Cheers George
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Blimey! I've no idea Baz. I'll whip the tank of tomorrow and try and work out which angle you've taken the shot from and compare. On a second viewing I think it's taken from below so I guess mine is going to pretty similar. Thanks for your input. Greatly appreciated. G
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Locktite is the way to go in my book, and my lifter was stiff until I realised it was fouling the tank. Windmill is 5 mins from me, should have dropped in for a coffee!

Dan

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H Bob - thanks for that. Let's see how I get on when I get to it. Dan - it was on your recommendation of E0 petrol that I called in at Windmill for a fill-up! Had I called on you we'd both have been involved in trying to sort the problems so it would have been a bit more than a coffee! George
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I have a garage and spanners and am not afraid to use them!.... although I was prob at work when you passed! I don't know if you read but BP weren't categoric about their ultimate being E0 from Southampton, I've emailed them again for further clarification. In the meantime the esso garage in Chard, or Seaton may also sell E0 I've written to esso about that too!

ps the clutch nut used to undo regularly on my jubilee back in the day, I now use a rattle gun and Locktite!

Dan

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There should be no hair pin loop in your cable George. It sounds like it has been fitted back to front. The inner cable nipple fits into the adjuster while the outer cable is captive in the recess on the end of the lifter arm, as per the photo from Barry. The cable then pokes straight out the front up to the de-comp lever on the bar.

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Managed to make a spring washer from an old flat washer. Hope it works. Did it up good and tight plus Loctite. Did not have time to look at the lifter but Paul's comment plus Baz's pic will be very helpful when I get on to it. After-thought - I've had another look at Baz's pic and managed to visually separate the cables. I'm certain that mine has been fitted back to front as Paul suggests. It definitely goes to the rear of the bike and loops back on itself.Thanks guys.
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Previously Dan Field wrote:

Looks like mines on backwards too but it woks fine.

i,ve also had trouble with valve lifter cable being stiff and the odd one snapping.so some years ago i bought all the stuff off venhill cables and now make all the cables on my single so all have no tight bends and with the nylon inner sleeve are smooth.i don,t buy off the peg cable

tony.

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Hi guys - I haven't forgotten you! The short time I've had to work on it today has been sorting out the clutch problem, readjusting the cable and adjusting the primary chain. Hopefully tomorrow the tank will be off and I'll investigate the routing of the lifter cable. George
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Right. Tank is now off and although I've photographed the lifter arrangement the computer/camera combination has decided not to work. Very definitely the cable disappears towards the rear of the bike. I have to say that the recess in the lifter arm looks like it's made for a nipple (therefore current set up is correct) but I suppose it could be for the stop on the end of the Bowden cable (current set up wrong). Does anyone have a definitive view on this?
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Previously George Phillips wrote:

Made pic b&w. Hope it works. George
George the imageshownpreviously is correct. Think of it asmoving the exposedend of the control cablefrom oneend to the other.... What I do see onyour install is alot ofcableties... thebettersolution wouldbe rubber strapsasavailable (EBay) and used on machines of acertain period (mainly BSA. Theyallowthe cable tolay inalessrigidway, and take up changes in position due to steering movement etc. (You fit the strapto the framethen create a loop with the remaining tail to attach thecable to).
I may be wrong but It alsolookslike your reverse installedcablescrolls over theframe top tube whichwill alsoadd friction, keep them straight wherever possible and flare out just in front of the tank and close to the steering head (preferably inside theforkstokeep theflowniceup onto the bars without the possibility of trapping on thelockstops. Ifyour decompress lever is of the type under thebarsthismaynot be possible).I trust a shorter cable willbeprocured,but don't forget lockto lock freedom.Try laying thecable inthe position keepingcurves as wideradius as possible andmaintain the"horizontal" linebetween the twofixedends constant, thenattaching itwith said straps in appropriatelocations. Thebarrelspringcan becomespringbound if too much movementisgenerated. Make sure youhavetheadjustmentright tolift thevalve sufficiently to crack theseal anddecompress.
The more you constrainacontrol cable thehigher theoperatingresistance. smiley
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George, if you are still in doubt as to the advise we are giving you, have a look at the valve lifter cables the club supplies in the N.O.C. shop. In several pictures, the adjuster can be seen on the cable the correct way around, not like the one in your picture. Perhaps the club ones are arse about too.

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Just removed cable. The nipple had indeed let go. Turned it all round the other way as per Baz's pic. Cut it all shorter. Fitted a screw-on nipple (well - sort of!). Adjusted it and it's lovely. No forcing at all. Many thanks guys. You've rescued me once again! George
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Hi Paul and Jonathan. I don't doubt the advice I'm being given, Paul. It's simply that the nipple nestled so neatly in the end of the valve lifter lever that it looked like it was made for it. I see now that it isn't. Thanks for your comments, Jonathan. All the ties were there when I bought it courtesy of the re-builder. As was this valve lifter set-up. I'm slowly working through the various issues so cable ties can now be added to my list! George

 


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