Clutch Cable Replacement
 

I've got a 2004 UK XT660X with broken clutch cable.

Can anyone guide me through replacing it? Bear in mind my mechanical knowledge is somewhere between limited and ok! Visual guides are ideal!

To get the old one off, start at the clutch end. Pull the rubber boot back and loosen the two adjuster nuts to give plenty of slack (get as much slack at the lever while you�re at it). Slide the cable out of the support bracket, bend the tab up on the release arm and unhook it. At the bars, turn the adjusters so the slot both line up and pull the cable out from the perch and then unhook it from the lever.

Before you pull out the whole cable, it�s a good idea to tape the lever end of the new one to the release arm end of the old one so you can pull the new one through as the old one comes out. Doing this also ensures the cable routing stays the same. Pull everything out from the handlebar end of the bike. You may need to cut, or loosen any cable ties and watch for snagging on the wiring harness.

Fitting is the exact reverse. Start at the lever and get that sorted, then move to fixing it at the release arm. Slip it back in the support bracket and adjust as necessary.

Set the free-play to around 10-15mm. Make sure a good few mm of thread is showing at the lever adjuster before you start to allow you to adjust both ways if necessary later on. Then try do the bulk of the initial adjustment at the release arm and leave the lever end for fine tuning and accommodating cable stretch and wear in the clutch plates as time passes.