Ducati Hyperstrada Forums Ducati Hyperstrada Motorcycle

Go Back   Ducati Hyperstrada Forum > Ducati Hyperstrada Forum > Mechanical and Technical

Mechanical and Technical Mechanical and technical topics, help, and discussions


Reply
 
LinkBack Thread Tools Display Modes
Old June 15th, 2017, 02:44 AM   #1
Senior Member
 
zibbit u2's Avatar
 
Joined: Jan 2015
From: Victoria BC Canada
Posts: 457

I Ride: 04 WR450 Supermoto, and 13 Hyperstrada
DIY : Clutch Cable Replacement Guide

For all you 821/939 Hypers out there, here's a quick and dirty guide to removing and installing the clutch cable on your bike. For the most part its pretty straight forward, but I figured I'd add this to the databank on this site.

Total time it took me to complete the swap was about 30 mins (including taking photos)

Tools you'll need:



5mm T-handle
5mm Allen Wrench
4mm Allen Wrench
3mm Allen Wrench
1 inch Crescent Wrench
24mm Wrench

Not pictured is a beer.

Optional Step 1: Remove the RH side tank cover. I only removed it for ease of taking photos, but there should be enough room to work with it still in place.

Step 2: Start off by removing the clutch cable clamp bolt, and the two bolts holding the headlight pod into place. Marked on the picture below:



Step 3: Pull straight up on the headlight assembly to disconnect it from the two rubber grommets on the upper triple tree. This will give you a little room to work without damaging the wiring behind that headlight. If it's the first time it's been removed, it'll require a little force. One of the two grommets are pictured below:



Step 4: Now Remove the cable from the clutch arm clevis on the engine case. To do this I used a crescent (adjustable) wrench and rotated the arm CCW to allow the cable to be disconnected. After you have the cable disconnected remove the bolt and clutch cable retainer bracket marked in the photo.



Step 5: Now go back to the handlebar and make a mental note of how the adjuster appeared before you touched it then rotate the adjuster just enough to align the slot with the clutch lever perch. Once the slot is aligned, withdraw the cable from the lever and perch.



Step 6: Now start to withdraw the cable from the bike. You pretty much have to untangle the clutch cable from the mess of headlight wiring, then remove the cable clamp, then feed the cable out of the bike. Everything will exit the bottom of the machine. It's kinda a PITA to do because of the hard section on the cable assembly won't allow it to happen any other way.



Optional Step 7: Beer o'clock 1/2 way there.

Step 7: Compare the length of both the outer shielding and how much the cable protrudes from the shielding. Try to make the new cable match the old setup.



Step 8: Start feeding the new clutch cable into the engine compartment. Pay note that the cable MUST pass behind (or inboard) of the Crank Case vent line (pictured below). Once the cable is around the vertical cylinder head, make the 90 degree corner and start feeding the cable towards the front of the bike just inboard of the trellis frame.



Step 9: With the clutch cable pointing straight out the frame near the radiator, install the clutch cable clamp removed in Step 2. Now install the Cable retaining bracket removed in Step 4 on the engine case. WARNING It's a real SOB to do it behind the header pipe.

Step 10: Now feed the cable behind the headlight assembly, making sure you're not pinching any wires, and that it rests in the slot on the backside of the headlight assembly. (it's the red-ish coloured one in the picture)



Step 10: Now reinstall the cable into the clutch lever and perch on the bars, then rotate the adjuster to approximately where it was before you touched it.

Step 11: Again using the crescent wrench, rotate the clutch arm CCW to reinstall the cable into the clutch arm on the engine case.

Step 12: Reinstall the headlight assembly and the fuel tank side cover if you removed it. A little trick, a little dish soap or lube goes a LONG way with the two headlight grommets. They sometimes can be a PITA. Don't forget to reinstall the two little bolts underneath the headlight assembly.

ANNNNNNNNDDDDD Done. Go enjoy the light feeling clutch again (if you didn't have too many at optional step 7 ).. Don't forget to check that your clutch engages properly before playing in traffic.
zibbit u2 is offline   Reply With Quote
 
Old June 15th, 2017, 03:33 AM   #2
Senior Member
 
Joined: Jun 2014
From: Boston
Posts: 700

Thanks for taking the time. Going to file this one away.
appliance821 is offline   Reply With Quote
Old June 15th, 2017, 06:59 AM   #3
Senior Member
 
monocog007's Avatar
 
Joined: Oct 2015
From: Minnesota
Posts: 476

I Ride: 13' Hyperstrada, 00' M900Sie
Awesome, love the write up. You do a great job of laying out all the details in an easy to digest way.
monocog007 is offline   Reply With Quote
Old June 15th, 2017, 09:06 PM   #4
Senior Member
 
Stradasphere's Avatar
 
Joined: Dec 2012
From: Central Washington
Posts: 280

I Ride: was Monster soon Hyperstrada
Nice write up. I just replacement my cable about 2 weeks ago. I was able to slip the cable behind the headlight with out moving it. But did pull the fuel tank which made it much easier to run the cable. That step took a little time but figured I would do the air filter replacement at the same time.
Stradasphere is offline   Reply With Quote
Old June 15th, 2017, 09:30 PM   #5
Senior Member
 
Joined: Jul 2014
From: California
Posts: 962

I had to replace mine as well. I used dry graphite lube on the new cable and it's been more than 6000 miles since then with no issues.

You went carbon crazy on the hyper! haha
kuksul08 is online now   Reply With Quote
Old June 15th, 2017, 10:28 PM   #6
Senior Member
 
zibbit u2's Avatar
 
Joined: Jan 2015
From: Victoria BC Canada
Posts: 457

I Ride: 04 WR450 Supermoto, and 13 Hyperstrada
Thanks appliance821 and monocog007.. Yeah, I definitely wouldn't pull the tank unless I had other jobs to do at the same time.
zibbit u2 is offline   Reply With Quote
Old June 16th, 2017, 07:49 AM   #7
Junior Member
 
ericrobinson's Avatar
 
Joined: Jul 2016
From: Toronto
Posts: 11

I Ride: 2016 Ducati Hyperstrada 939
Perfect timing. I just noticed mine is frayed near the lever. Could be my fault, as I replaced the lever with a Pazzo, and may have roughed it up a bit.
ericrobinson is offline   Reply With Quote
Old June 16th, 2017, 08:40 PM   #8
Senior Member
 
zibbit u2's Avatar
 
Joined: Jan 2015
From: Victoria BC Canada
Posts: 457

I Ride: 04 WR450 Supermoto, and 13 Hyperstrada
Did a little over 300 km on the hyper today after the cable replacement, and oh how I love the buttery smooth clutch pull. I think my cable replacement was way overdue (even though it wasn't broken) @ 19,000 km.

Upon further inspection of the old cable, it feels like the outer shielding on mine was out of round or pinched in a few places causing the cable inside to bind up a bit. There wasn't any signs of damage to the exposed inside cable on either end, or any obvious damage to the shielding.
zibbit u2 is offline   Reply With Quote
Old June 19th, 2017, 07:02 AM   #9
Senior Member
 
Joined: May 2017
From: Philadelphia USA
Posts: 131

I Ride: 2013 Hyperstrada
I got my new cable installed yesterday. I didn't bother with removing the headlight housing as it wasn't difficult to thread the cable between the triple tree and the housing.
I did remove the little triangle of black body trim beneath the gas tank. It made it easier to see my way under the tank when feeding the cable forward from the engine.
I had to adjust the cable with the lever adjustment screw to all the way out to get the same play I had before. Originally this was only about half way out.

It all seems good though. Rode the bike and no problems with operating the clutch. At full steering lock in either direction the cable isn't stretched or kinked.

I'm so happy to be riding my Ducky again! Quack quack quack!
philthymike is offline   Reply With Quote
Old June 19th, 2017, 06:16 PM   #10
Senior Member
 
Joined: Jun 2014
From: Boston
Posts: 700

Quote:
Originally Posted by philthymike View Post
I got my new cable installed yesterday. I didn't bother with removing the headlight housing as it wasn't difficult to thread the cable between the triple tree and the housing.
I did remove the little triangle of black body trim beneath the gas tank. It made it easier to see my way under the tank when feeding the cable forward from the engine.
I had to adjust the cable with the lever adjustment screw to all the way out to get the same play I had before. Originally this was only about half way out.

It all seems good though. Rode the bike and no problems with operating the clutch. At full steering lock in either direction the cable isn't stretched or kinked.

I'm so happy to be riding my Ducky again! Quack quack quack!
I'd set the lever adjuster back to center and set the play roughly with the secondary adjuster. For some reason this made my clutch a little smoother, and you'll room for more adjustments at the lever.
appliance821 is offline   Reply With Quote
Reply

  Ducati Hyperstrada Forum > Ducati Hyperstrada Forum > Mechanical and Technical

Tags
cable, clutch, diy, guide, replacement



Thread Tools
Display Modes


Similar Threads
Thread Thread Starter Forum Replies Last Post
Ducati Hypermotard 821 clutch fix - the definitive guide bayotte Mechanical and Technical 44 November 13th, 2017 06:24 AM
Clutch Cable cjc045 Mechanical and Technical 20 June 14th, 2017 05:49 PM
Hyper 821 Touring seat - Top Case - side tankpad - clutch cable - clutch lever rizoma silenthunter Classifieds 1 May 26th, 2016 10:01 PM
Clutch cable failure st2cmack Mechanical and Technical 12 July 12th, 2015 11:22 AM
Clutch Cable Snap carib821 Mechanical and Technical 41 March 31st, 2015 06:15 PM


Ducati Hyperstrada Facebook Ducati Hyperstrada Twitter Ducati Hyperstrada RSS Feed



Ducati Hyperstrada Motorcycle Forum
Copyright © 2012-2014 HYPERSTRADA.COM • All rights reserved.