MotoMaster Motorcycle Clutch Cable for Suzuki GN 125 (OEM 58200-05392)

1. Product Overview

This MotoMaster clutch cable is designed as a direct replacement for specific Suzuki GN 125 motorcycle models. Manufactured to original equipment specifications, it ensures a precise fit and reliable performance for your motorcycle's clutch system. The cable features a durable construction with a high-quality outer wire, Teflon lining, and a corrosion-retardant alloy inner wire, engineered to resist friction, prevent premature breakage, and maintain flexibility in various temperatures.

Figure 1.1: The MotoMaster Motorcycle Clutch Cable. This image displays the complete clutch cable, showcasing its black outer casing and metal end fittings.

2. Compatibility

This clutch cable is specifically compatible with the following Suzuki GN 125 models. Please verify your motorcycle's model and year against this list before installation.

Figure 2.1: Compatibility table for the MotoMaster clutch cable. This table lists the specific Suzuki GN 125 models and their corresponding production years that are compatible with this clutch cable.

3. Setup and Installation

Replacing a motorcycle clutch cable requires mechanical aptitude and specific tools. If you are not confident in your ability to perform this task safely and correctly, it is highly recommended to seek assistance from a qualified motorcycle mechanic.

3.1 Safety Precautions

• Ensure the motorcycle is stable on a stand and the engine is off and cool.
• Wear appropriate personal protective equipment, including gloves and eye protection.
• Refer to your motorcycle's service manual for specific instructions and torque specifications.

3.2 Installation Steps (General Guide)

1. Preparation: Loosen the clutch cable adjusters at both the lever and engine ends to provide maximum slack.
2. Disconnect Old Cable:
   • At the clutch lever, remove the cable end from the lever perch.
   • At the engine side, locate the clutch arm and disconnect the cable end.
   • Carefully remove the old cable from its routing guides on the motorcycle frame.
3. Install New Cable:
   • Route the new MotoMaster clutch cable along the same path as the old cable, ensuring it does not kink or interfere with moving parts (steering, suspension, etc.).
   • Connect the engine end of the cable to the clutch arm.
   • Connect the lever end of the cable to the clutch lever perch.
4. Adjust Cable Slack:
   • Adjust the cable tension using the adjusters at the lever and/or engine until the clutch lever has the recommended amount of free play (typically 2-3mm at the lever tip). Refer to your motorcycle's service manual for the exact specification.
   • Ensure the clutch fully disengages when the lever is pulled and fully engages when released.
5. Final Checks:
   • Check for smooth operation of the clutch lever throughout its travel.
   • Ensure all adjusters are tightened securely after adjustment.
   • Start the engine and test the clutch operation at low speeds in a safe area before riding.

Figure 3.1: Close-up views of the clutch cable ends. The left image shows the threaded adjuster end, typically connecting to the engine's clutch arm. The right image shows the barrel nipple end, which connects to the clutch lever.

4. Operating the Clutch Cable

The clutch cable transmits the force from the clutch lever to the clutch mechanism on the engine, allowing for engagement and disengagement of power to the transmission. Proper operation relies on correct installation and adjustment.

• Smooth Engagement: A properly adjusted cable will allow for smooth and progressive clutch engagement when the lever is released.
• Full Disengagement: When the clutch lever is fully pulled, the clutch should completely disengage, allowing for gear changes without grinding.
• Free Play: Maintain the recommended amount of free play at the clutch lever to prevent premature clutch wear or incomplete engagement/disengagement.

5. Maintenance

Regular maintenance extends the life of your clutch cable and ensures safe operation.

• 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 engine.
• Lubrication: Although MotoMaster cables are pre-oiled with a special compound and feature a polyimide lining to reduce friction, periodic lubrication with a suitable cable lubricant can further enhance smooth operation and longevity. Use a cable luber tool to apply lubricant into the cable housing.
• Adjustment: Check and adjust clutch cable free play regularly, as cables can stretch slightly over time.
• Cleaning: Keep the cable and its routing free from dirt and debris. The special compound used in MotoMaster cables helps resist dust attraction.

Figure 5.1: View from a motorcycle handlebar. Regular inspection of the clutch lever and cable routing is essential for safe operation and maintenance.

6. Troubleshooting

If you experience issues with your clutch, consider the following common troubleshooting steps:

• Stiff or Sticky Clutch Lever:
  • Cause: Lack of lubrication, dirt ingress, or internal cable damage.
  • Solution: Lubricate the cable. Inspect for kinks or damage. If lubrication does not resolve the issue, the cable may need replacement.
• Clutch Not Fully Disengaging (Grinding Gears):
  • Cause: Insufficient cable slack, stretched cable, or incorrect adjustment.
  • Solution: Adjust cable free play to the manufacturer's specification. If the cable is stretched beyond adjustment limits, it requires replacement.
• Clutch Slipping (Engine Revs but No Power to Wheel):
  • Cause: Too much cable tension (no free play), preventing full clutch engagement.
  • Solution: Ensure there is proper free play at the clutch lever. If the issue persists, it may indicate worn clutch plates, which are not related to the cable.
• Broken Cable:
  • Cause: Wear and tear, fraying, or sudden excessive force.
  • Solution: The cable must be replaced immediately. Do not attempt to repair a broken cable.

7. Specifications

8. Warranty and Support

For information regarding product warranty or technical support, please contact the seller or MotoMaster directly through their official channels. Refer to your purchase documentation for specific warranty terms and contact details.

You can visit the MotoMaster Store on Amazon for more information or to contact their support.