1. Introduction
This manual provides essential information for the installation, operation, and maintenance of your MotoMaster Motorcycle Clutch Cable. Please read this manual thoroughly before installation to ensure proper function and safety.
2. Product Overview
The MotoMaster Motorcycle Clutch Cable is engineered to meet or exceed OEM specifications, providing a reliable and durable replacement for your motorcycle's original clutch cable. It features high-quality materials designed for longevity and smooth operation.
Figure 2.1: The MotoMaster Motorcycle Clutch Cable, shown coiled. This cable is designed for precise fitment and reliable performance.
Key Features:
- OEM Standard Production: Manufactured to original equipment specifications for a perfect fit.
- High-Quality Materials: Features a durable outer wire with Teflon and a corrosion-retardant alloy inner wire.
- Enhanced Durability: Production methods reduce friction and increase resistance to premature breakage.
- Weather Resistant: Oiled with a special compound to resist freezing in low temperatures and dust attraction.
- Polyimide Lining: Inner cable and metal components coated with high-quality polyimide lining to protect against friction and wear.
3. Compatibility
This MotoMaster Clutch Cable (OEM Part Number: 5KS-26335-00) is specifically designed for the following motorcycle model:
- Yamaha XVS 1100 A Drag Star Classic (Years: 2000-2007)
Please verify your motorcycle's make, model, and year against the table below to ensure proper fitment before proceeding with installation.
Figure 3.1: Compatibility table confirming fitment for Yamaha XVS 1100 A Drag Star Classic models from 2000 to 2007.
4. Safety Information
Always prioritize safety when working on your motorcycle. Improper installation or maintenance can lead to serious injury or damage to the vehicle. If you are unsure about any step, consult a qualified motorcycle mechanic.
- Wear appropriate personal protective equipment (PPE), including gloves and eye protection.
- Ensure the motorcycle is stable and securely supported before beginning any work.
- Disconnect the battery if working near electrical components.
- Keep hands and clothing clear of moving parts.
- Dispose of old parts and fluids responsibly.
5. Installation Guide
This section outlines the general steps for replacing a motorcycle clutch cable. Specific procedures may vary slightly depending on your motorcycle's configuration. Refer to your motorcycle's service manual for detailed instructions.
Tools Required:
- Wrenches (various sizes)
- Pliers
- Screwdriver (if needed for fairings/covers)
- Cable lubricant (optional, but recommended for new cable)
Installation Steps:
- Prepare the Motorcycle: Park the motorcycle on a level surface using its center stand or a suitable lift. Ensure the engine is off and cool.
- Locate the Clutch Cable: Identify the clutch cable's routing from the clutch lever on the handlebar down to the clutch arm on the engine.
- Remove the Old Cable (Lever End):
- At the clutch lever, loosen the cable adjuster and remove the cable end from the lever perch.
- Carefully slide the cable nipple out of the lever.
Figure 5.1: Close-up view of the clutch cable end designed to connect to the clutch lever.
- Remove the Old Cable (Engine End):
- At the engine, locate the clutch arm. Loosen any retaining nuts or bolts that secure the cable.
- Remove the cable end from the clutch arm.
Figure 5.2: Close-up view of the clutch cable end designed to connect to the clutch arm on the engine.
- Route the New Cable: Carefully route the new MotoMaster clutch cable along the same path as the old one, ensuring it does not kink or interfere with other components.
- Install the New Cable (Engine End): Connect the engine end of the new cable to the clutch arm, securing it with any retaining hardware.
- Install the New Cable (Lever End):
- Insert the cable nipple into the clutch lever.
- Secure the cable into the lever perch and adjust the cable adjuster to take up most of the slack.
Figure 5.3: Both ends of the MotoMaster clutch cable, showing the lever and engine connection points.
- Adjust Cable Free Play:
- Adjust the cable at the lever and/or engine side until there is approximately 2-3mm (0.08-0.12 inches) of free play at the clutch lever before the clutch begins to engage.
- Ensure the clutch fully disengages when the lever is pulled and fully engages when released.
- Test Operation: Start the motorcycle and carefully test the clutch operation. Ensure smooth engagement and disengagement. Check for any binding or unusual feel.
- Secure Components: Tighten all fasteners and ensure all covers or fairings removed during installation are reinstalled correctly.
6. Operation
Once installed and properly adjusted, the MotoMaster clutch cable will provide smooth and consistent clutch operation. Regular inspection and proper use will ensure its longevity.
Proper Clutch Usage:
- Always pull the clutch lever fully to disengage the clutch before shifting gears.
- Release the clutch lever smoothly and progressively when engaging gears to avoid sudden jerks.
- Avoid "slipping" the clutch unnecessarily, as this can cause premature wear to the clutch plates and cable.
- Do not ride with your hand resting on the clutch lever, as this can apply slight pressure and cause clutch drag.
Figure 6.1: View from a motorcycle rider's perspective, showing the handlebars and controls, including the clutch lever.
7. Maintenance
Regular maintenance of your clutch cable is crucial for optimal performance and extended lifespan. Follow these guidelines for proper care:
- Regular Inspection: Periodically inspect the entire length of the cable for signs of fraying, kinking, rust, or damage to the outer casing. Pay close attention to the ends where the cable connects to the lever and the engine.
- Lubrication: Lubricate the inner cable at least once a year, or more frequently if riding in dusty or wet conditions. Use a dedicated cable lubricant and a cable luber tool to ensure the lubricant reaches the entire inner wire.
- Adjustment Check: Regularly check the clutch lever free play. If it changes significantly, readjust the cable as described in the installation section.
- Cleaning: Keep the cable and its ends clean from dirt and debris.
8. Troubleshooting
This section addresses common issues related to clutch cable performance. If you encounter problems not listed here, or if solutions do not resolve the issue, consult a professional mechanic.
| Problem | Possible Cause | Solution |
|---|---|---|
| Clutch feels stiff or sticky | Lack of lubrication, dirt/debris in cable, kinked cable, worn inner wire. | Lubricate the cable. Clean cable ends. Inspect cable for kinks or damage; replace if necessary. |
| Excessive free play at clutch lever | Cable stretching, improper adjustment. | Adjust cable free play at the lever and/or engine side. If stretching is severe, consider replacement. |
| Clutch does not fully disengage (drags) | Insufficient free play, cable stretching, worn clutch plates (less likely if new cable). | Increase free play. If problem persists, inspect clutch plates and components. |
| Clutch slips (does not fully engage) | Too much free play, worn clutch plates, oil contamination. | Decrease free play. Inspect clutch plates and oil. |
| Cable breaks | Extreme wear, fraying, improper routing, manufacturing defect. | Replace the cable immediately. Inspect routing for sharp bends or pinch points. |
9. Specifications
Detailed specifications for the MotoMaster Motorcycle Clutch Cable:
- Brand: MotoMaster
- Model Number: 155-256
- OEM Part Number: 5KS-26335-00
- Compatible Models: Yamaha XVS 1100 A Drag Star Classic (2000-2007)
- Item Weight: Approximately 1.26 pounds (0.57 kg)
- Package Dimensions: Approximately 10.98 x 9.57 x 1.06 inches (27.89 x 24.31 x 2.69 cm)
- Material: High-quality outer wire with Teflon, durable inner wire with corrosion-retardant alloy, polyimide lining.
- Package Quantity: 1 Piece Clutch Cable
10. Warranty and Support
MotoMaster products are manufactured to high standards. For any questions regarding your clutch cable, including compatibility or installation, please contact MotoMaster customer support.
You can find more information and contact details by visiting the official MotoMaster store:
