Clutch Cable project

[KKXR400R]

Ok heres the deal. I got a good deal on some zeta levers but there were made for an 04 CR250. I probably should have stuck with the stock levers but sometimes I think I enjoy being tormented with projects. I tried to adapt it to my bike but found Honda uses an on the fly adjustment and changed the perches. I went out and got an 04 perch. It fits great on my bike but I found that the cable for the 01 is too short and I'm gonna need some more adjustment in the cable for more free play. heres a few questions.

1. Would an 04 clutch cable fit through the left side case to engage the clutch Lifter?

2. Would it be long enough so I can adjust for more free play?

The clutch perch part numbers are the same from 04-07 but the clutch cable part number is different from the 04's to the 05-07's. I think there was a change in the routing into the cases. Any help would be great. If someone has an 04....please chime in and I'll be your freind. Pictures and measurments would be great also. I'm already too far in to go back to stock so thats pretty much out of the question. thanks in advance.

-Kevin-

[Vintage Dave393]

Open up the ferrule on the cable, slide it off the plastic covering. Then trim the plastic covering back the necessary amount and unroll the necessary amount of cable sheath. Cut that off and then slide the ferrule back onto the remaining plastic cover. Crimp to fit. Walla! Cable now has more length.

Here's a pictoral on it from Super Hunky's site. Start about half-way down.

Oh yeah, it's free

[KKXR400R]

Thats a great read dave! I was thinking about cutting the housing but I didn't realize you can pop the metal end cap off. I will do this to get me going for a while. When I purchased this cable I was thinking a "heavy duty" would be the way to go......I HATE this cable. Its way too thick and bulky. In my haste to get this project completed I cut the adjusting nut off and got a few more mm's of adjustment out of it. I did this before I posted on here. Ya I know that was stupid but oh well, you live and learn. Anyways I'm gonna order an 04 clutch cable down the road and see if it works, unless someone pipes in before hand. I'll let keep everyone posted on how it works.

-Kevin-

[Florida 393]

Definately KB material here.

Bill