Throttle / clutch cables.

Hello,

Don't know if I've posted this yet, but I recently bought two parts (one former street and one former track) bikes, '87 and '89 CBR 600Fs. I'm in the process of semi-refurbing and rebuilding them into one for my own personal use. I'm most of the way there, short a few parts, and am having a few little problems.

So, I need to know exactly where the throttle cables, and clutch cables are routed, from the handle all the way to the carbs. A picture of inside the frame (with the tank/airbox off obviously) would be of great assistance, and I can't find anything similar on the internet. The reason I ask is that I can't seem to find a way to route them where they have enough slack to turn the bars from one side to the other, while not having so much slack that they fold/bind up and make the throttle harder to turn while turning the wheel.

Thanks!
-Matt

Wish I had a camera and I would snap some shots. They both essentially need to run back behind towards the ignition and around the neck at the peak of the frame.  My throttle cables stay snug under the side of the radiator cap, and the clutch is on the other side as well.  If I had a camera and didnt just put my fuel tank on I would take a picture for you.

So, behind the fork, under the igintion, around the stem and then above the frame (under the tank)?

Check out the pic in this ebay auction - maybe it'll help.

eBay Link

Instead of starting another thread only an hour or so after making this one, I'll just ask my next question in here.

How tight should the bolts for the lifter plate (over the clutch/springs) be? I got them too tight the first time (so much that when I pulled the clutch lever, it had no effect since the plate was already pushed in all the way.) When I backed them out from being so tight, they felt insecure. So now I'm worried that if I go too tight my clutch will slip, and too loose and they'll fall out.

Any first hand experience with finding the sweet spot for them? My clymer's manual (I'll probably never buy another clymers now that I've had one) just says tighten them 'securely'.

Thanks!
-Matt

Which part is the lifter plate?  The part by the handlebars or the part by the actual clutch?

Looking at that picture, it looks like the cables AREN'T going around the stem, just around the forks. I'll just have to test both ways and see what fits best for me (I was trying to put them through the holes in the frame, no wonder it wouldn't work the first time.)

The lifter plate is inside the crankcase cover, it's what (by default, with the help of 4 springs) keeps pressure on the clutch plates unless the clutch lever is pulled, then it pushes the clutch plates apart enough for them to have room to spin freely. The bolts I'm talking about are the four that run through the lifter plate, through the springs, and into the rear portion of the clutch holder.



Needing some sort of tension spec for the bolt numbered 17, and the lifter plate is 14.

About the cables -

The holes in the frame are meant to line up with the 'tubes' on the top of your airbox, so nothing goes through there.

Look on page 216 of your Clymers and it shoes the airbox installed with (my guess) one throttle cable on each side of the stem and the radiator filler.

The clutch cable is so short, There's probably only one way it can go. Can't find any pictures right now, though.

The Honda shop manual (Honda, not Clymer or Haynes) that I have doesn't give a torque.  It just says "Tighten the bolts of the punch marks on the plate first, and then tighten the other bolts".

Just had time to do a quick sketch...
Hope this works... have another couple to post shortly...


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And this one...


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last one... hope this is useful.


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Those pictures are AMAZING. That definitely clears it up.

Where could I get a set of those pics? Or what manual is that from? Lots of people I talked to said Clymers was the best, but I guess they havn't seen whatever manual that's from.

Dang. Britton for President! Those are awesome.

I love my Clymer.  Gives more than enough information to rebuild this bike.  I don't really know much about clutches so I can't help in that department.  Sorry.

here is a pic of how my cables are routed.
 
the throttle cables are routed right of the steering head under the top triple over the frame rail.
 
the clutch cable is routed behind the key fob and snakes down the side of the frame.
 
the choke is running through the air intake in the frame. note, i do not use a choke or run the airbox.

These are all great posts, thanks for all the help everyon!

Now if only I could figure out those clutch bolts.

Also make sure the clutch cable goes through the rectangular wiry-brace cable-holdin thing that's on the front right of the frame.

The pix are from the Honda Shop Repair manual.  Try Helm Inc. (Helminc.com, I think) or eBay if you want a copy.  Haynes and Clymer have their strengths (I have both) but the genuine manual is best - and more expensive.