Clutch Cable SNAPS

What do you do when your clutch cable pulls out of the end crimp, and you are 200 miles from home?  You bodge it.  On close inspection the crimp end just pulled out of its solder.  The wire itself wasn't bent over in the channel provided to give extra strength.

Luckily the cable was long enough to tolerate some of the sheath being cut off.  This was harder than it looked, since the outer casing is made of really hard spring steel.  We broke a pair of dikes cutting it.  I then took the extra-long exposed cable and lashed it to the handle.  Vice grips were used to hold it in place, while a hose clamp was applied as extra protection.  The travel was compromised so the clutch dragged a lot, but enabled me to catch it in gear and get going when stopped.  It held the whole way home.



It was easy as long as I didn't have to stop.  Traffic was a problem, but not insurmountable.  Once I got the procedure down, I was able to push myself and catch it in first.

Sunbeam S7 Deluxe tuned and adjusted

The engine has been hard to start, and hasn't seem to had the right amount of torque at low revs.  I figured that it was too far advanced, and I should back it off some.  I'm not halfway between the original mark on the distributor and where the book said to set it.  It runs much better.

Also, the clutch travel wasn't right, so I took the blob of tape off the handlebar to find that someone had adjusted the clutch cable with a washer holding the sheath out away from the handle.  That explained a lot.  I removed the bodge, and then remembered that the clutch slave arm wasn't symmetrical.  Its actually made so that its bent a little and can be put on either direction.  This meant pulling the rear fender out of the way, and undoing the jam-nut and screw that holds the arm in.  With that done, I flipped it around and then readjusted the clutch adjuster so that I got better travel and engagement at about where I wanted it.  The clutch is much better now and the bike even shifts better since its disengaging better.  Previously it would clunk pretty loud when changing from 1st to 2nd.  Now its smooth.  Probably smoother than my Guzzi.

I still haven't taken it very far.  The engine runs hot even though its running a little on the rich side.  The rings are likely still rather tight.