Newb with a 2-Stroke, RD400 Clutch cable removal

[PalmerCole]

So I bought a 77 RD400 in really great shape, I'm not what you would call mechanically inclined, but figured this would be a good bike to learn on. I decided to install clubmans and now my cables are way too bunched, so now I'm rerouting them. Except I can't get the clutch cable out of the perch, I checked where the cable goes into the bike and I don't see an adjustor or anything, does anyone have any suggestions to get more slack? I've already loosened the adjuster at the lever as much as it will go. Also I'm going to have to reroute the throttle and brake lines, are there any problems I need to watch out for when routing those? Like the brake cable, can I loosen the bolt on the metal arm where the cable meets the master cylinder without having to bleed the lines? Any help would be greatly appreciated, I'm having a blast working on it, even though its minor stuff for now, and can't wait to make more progress

 

[Redbird]

Once you have the adjuster at the lever all the way in, take the pivot bolt out of the lever and remove it from the perch. You'll be able to remove the cable from it easily then. Simply do the reverse to reinstall.

When rerouting the throttle cables, make sure they don't bind or pull at full lock on both sides. This could cause the throttle to stick. In fact that goes for any/all cables when rerouting.

If you loosen the brake line at the master cylinder just enough to rotate it, and don't squeeze the lever while it's loose, there's a good chance you'll be ok.


Welcome to the 2stroke Gang

 

[PalmerCole]

Awesome thanks! Yeah I figured out the pivot bolt after tinkering with it awhile, finished rerouting the cables and all is good, except that my clutch seems a little stiffer, I've been messing with the adjustment but it still seems a few stops stiffer than before, any suggestions?

 

[Redbird]

You've probably got the cable curved to tightly somewhere.

 

[PalmerCole]

Yeah I have it going from the grip over/behing the gauges through the forks on the right side then looping back towards the left and under the tank and on to the transmission. It's the best I can do for now, unless you have any other suggestions. Though I'm an idiot and during the process of doing this I left the key on and drained the battery, the bike died on me last night and I had to push it home, left it on the trickle charger and it died again on me today and had to tow it home, so looks like new battery and possibly a new rectifier are in order.

 

[bradj]

hide the slack under the tank and soffen the curve to the motor my man where is pictures of this rd

 

[PalmerCole]

Thanks Redbird and Bradj, There seems to be a thin film of oil on the left side of the bike, need to check for a leak. But the bike does look nice next to my neighbor's rover.


20130414-DSCF5188 by Remlap Eloc, on Flickr

It seems that I'm having issues with batteries lately as my camera died before I could get any more shots. I'll post more later.