Clutch cable (750J) looking messy - thoughts please

[MikeH1A]

I managed to snap my clutch cable whilst out on my last ride. It broke at the point where it attaches to the lever. Today, I went to take the cable off and found things to be looking a bit messy where it attaches to the arm down at the motor end.

Firstly, the end of the cable and the arm have some corrosion on them - ? water has been getting in there somehow.

Secondly, the spring is out of shape and I'm guessing I'll need to replace this (Are they easy to get?)

Thirdly, there is engine oil sitting at the bottom of the housing there and coating some of the pieces. How would that be leaking into there? Am I perhaps missing some sort of seal there?

Also, the cable is frayed where it has obviously been rubbing against the underside of the tank. Any advice on the correcting routing of the cable?

I'm going to try and attach pics of the offending pieces but bear with me if it doesn't work out well. My last attempt at attaching pics from photobucket only ended up with a link rather than the pics themselves. They seem to have changed something since my earlier attempts.

Thanks for any help.

[Alan H]

If it's the original cable, no wonder it's knackered.
Get a new one every 20 years or so to stop this happening you tightwad!!
Take the spring to your local auto shop and get something close until you get the right one.
With a new (lubricated) cable, it should work temporarily without a spring until you can get one.
part no. 09443-08001 - have a look on ebay for starters or cruzinimage maybe.
Have a look HERE (clicky) then select year, model, clutch etc.
A parts manual is very handy as it gives you an exploded diagram of every part on the bike. LIKE THIS

[MikeH1A]

A new one every 20 years??? You Brits must be made of money That's the first time I've had a look in there since I've owned the bike so a bit of sprucing up required obviously. Hadn't thought of cruisinimage - thanks

Any ideas why the oil is seeping in to there?

[oldjapanesebikes]

Any ideas why the oil is seeping in to there?

If you take a look at a parts listing, there is one oil seal (09285-25002) on bikes built after frame 18527 in the side cover. If that covers yours, then it's just a standard single lipped 25x34x6mm seal which you may be able to locate at a jobbers. As well the cap cover gasket (11495-31000) could also be the problem.

[tz375]

Water is seeping down the cable into that end fitting. Get a new soft rubber cap/cover for that end of the cable.

Ian hit the nail on the head. Either the seal is worn out or the end of the shaft is damaged or the gasket leaks. Oil mist is supposed to get through that open section at the top of the inner cover into the outer and from there it just gravity feeds into the end of the shaft.

[re5rotary]

You don't listen to what I say do you I told you about that when we did the last lot of work on the bike.... the sleeve the seal runs on is damaged and needs replacing along with the seal

T

[MikeH1A]

Thanks for the replies fellas.

I thought the rubber boot must of been at fault for that water to get in there. New one ordered.

Ian, I am interested in the seal and frame numbers you put up. My bike is in the early 12000s so quite a bit before the frame numbers you mentioned. Was there some difference then re seals and/or type of outer cover from the early models to the later ones?

T, sorry if it looked as though I wasn't listening. You know I'm not that rude I just recall you saying there were problems there and was a bit surprised when I opened the cover after the cable snapped. New one on the way.

Another question: If you look at the pic with the spring in situ - it looks as though it is hooked over the arm and ? should it be through that hole there. I'm guessing the PO may have hooked it there after it got munted and stretched.

Thanks heaps, Mike

[tz375]

Correct, but that's not the right spring either. Time to order a new one.

I stripped a motor recently and the side cover was full of oil. When I inspected the clutch pull rod I could see why. A PO must have held it with vice grips and it turned as they tightened or loosened the two nuts leaving deep gouges that oil just ran through the way that reality TV "stars" run through cash and friends.

[oldjapanesebikes]

Ian, I am interested in the seal and frame numbers you put up. My bike is in the early 12000s so quite a bit before the frame numbers you mentioned. Was there some difference then re seals and/or type of outer cover from the early models to the later ones?

I think so Mike, although I don't have one in front of me at the moment to be able to actually confirm.

[re5rotary]

Mikes clutch pull rod has the same problem, vice grips on the shaft where the seal would run Terry

[MikeH1A]

I've isolated the oil leakage. After being away for work for a week, I returned to find an stain under the bike that is about 40cm long and 15cm wide. I hadn't gotten around to fitting the new clutch cable or spring yet so left the cover off. The oil is coming from the hole at the bottom of the cover, i.e. the hole directly under the hook that the spring sits on - visible in the above photos. What is this hole for? I see there is engine oil in it and what seem to be happening is that it quietly spills over the top of the hole and leaks out. But why would oil be continually filling up this cavity when the bike is not doing anything?

Excuse my basic ignorance here but I am intrigued. So what happens with this oil when the bike is going does it continue to leak in there or is it diverted elsewhere when the motor is running?

Thanks for your thoughts.

[re5rotary]

I told you before we are rich your bike produces oil in the gearbox T

[MikeH1A]

It is without a doubt the most bizarre thing Seriously, it just sits there and the darn stuff just keeps slipping out over the top of that hole and oozes everywhere! Come on T, give me at least a pseudo-scientific explanation .... pleaseeeeee

[tz375]

Mike, there is no hole there on any of the half dozen covers I checked.

On yours, is that a pair of slots either side of the spring peg or is that just a small amount of residual oil. If they are actual holes, they are at or below the oil level and oil will indeed leak out. There should be no holes between that cavity and the main primary transmission cavity.

That said, I cannot guarantee that any of my side covers are from a J model, so it is always possible that a J is different.

[MikeH1A]

Thanks TZ. Yes it is a bit weird. In the above pics, the two "black" smudges at the bottom are actually slots or holes into the casing - not oil stains. You can stick a nail in there and it goes straight into oil.

I agree that it seems weird. I have been monitoring such cases for sale on ebay. All the ones I have seen are different in two respects. None have those slots or holes there and they all have a peg that sits out from the casing wall - to hold the spring I assume. Mine does not have a peg - it has a metal loop that it part of the casing over the holes there i.e. it seems an original cast piece.

So the mystery remains: what is this casing part off, what are those holes there for and what happens to that oil when I'm running the bike???

Any answers from anyone greatly received.