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A UK Site Dedicated To The Suzuki C800, VL800, VX800, M800, VZ800, VS800, C50, M50 Model Intruder / Boulevard / Marauder
 
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 * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*

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Mr Intruder
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PostSubject: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Sun Aug 19, 2012 7:40 pm

I started the preparation today for the fitment of my 14" ape hanger handle bars. I already have the apes, the throttle cable kit & new extended brake hose. So I decided today to attempt to re-route the clutch cable rather tan buy an extended one after Captain Crash reminded me that Freemo hadn't bought one but instead re-routed his clutch cable when he fitted his apes.

So here is how I got on.

In this first picture you can see how the the clutch cable originally routed around the back of the engine. The yellow arrow shows the cable routed up the back of the engine & the yellow one shows its route along the top of the engine frame. It is held in numerous places by re-usable cable ties which you will first need to remove.
You will find that you will need to undo/release the cable at one end so as to be able to re-route the cable & I would suggest you do that from the hand lever end as you will find that the other end will be the biggest bitch you could ever imagine to release.
After re-routing I would advise that you ensure that the internal cable is still moving freely by pushing and pulling the internal part with just a finger hold.




This is how it will look when it has been routed and I must thank Mr Suzuki for making the routing easier and neater at the clutch end by putting and angled kink in the cable. As you can see I have routed and cable tied the clutch cable to the rear of the PAIR valve & this holds the cable approximately 2.5 cm away from the head fins, so heat will not be an issue.




Here you can see the end result of this cable re-route, which is now with an extra 9" cable at the handle bar end and is now ready for the fitment of the ape hangers.




So today I have enjoyed tinkering with my bike as we had the kids around and I wasn't aloud out & I have saved money at the same time.
Hope you find this useful or interesting, Regards Dave.


Last edited by Mr Intruder on Mon Sep 24, 2012 8:56 am; edited 1 time in total
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captain crash
Mentally Deficient lunatic ..... & ..... Site Moderator
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Sun Aug 19, 2012 8:38 pm

As always an excellent write up and very useful information as well. The good thing about threads like this is that people often here that something can be done but when you get a writr up with pictures it gives people the written and pictorial evidence that gives them the facts and confidence to do that them selfs.

Good one Mr I

PS. When you putting the apes on mate?
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Bluesman
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Sun Aug 19, 2012 9:37 pm

I am reading this thread with great interest because this is something I would love to do. I am ok with the release of the ties and the cable at the lever end. I see the cable goes behing the pair valve and appears nicely looped with more slack at the lever end. Any chance of a little more detail as to where it goes between these 2 points ? I found this very helpful and the pics showed things as they are - thanks. My problem would be the brake lines I'm sure so I'm looking forward to that installment! Keep up the good work.

I think it's great that this journey started with Freemo, was encouraged by CC and culminated in today's write-up. True collaboration
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Mr Intruder
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Sun Aug 19, 2012 10:18 pm

John, from the PAIR valve it literally goes up and is cable tied to the frame at the first opportunity but as with the original install it is tied on the inner side of the frame. From there it runs behind the left side plastic cover that sits in front of the tank & then feeds straight through and out of the triple tree. The picture I have shown above doesn't actually do the available length justice, as it is pushed over to the right of the triple tree due to excess available length.

The brake lines can be purchased already made up but I am to tight for that so I have bought two throttle cable kits. When I do that section I will do a full right up, including exact lengths for internal cables and external sheaths that I have used in conjunction with 14" apes, as well as indicating which original parts will be used.

I will also do a full write up with pic's when I extend the electrical cables as well, so your not on your own buddy. When I have done all the separate threads I will culminate them in a single thread that covers a complete install.

It is surprising that so many people have apes on these bikes around the world, yet I can not find a single write up on how anyone has done it. So we will have to do yet another first at suzuki800.com
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alfie92
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Sun Aug 19, 2012 10:31 pm

Well done Dave,as always a good read and very informative.I agree with John

I think it's great that this journey started with Freemo, was encouraged by CC and culminated in today's write-up. True collaboration thats the good thing about this forum.
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Bluesman
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Sun Aug 19, 2012 10:40 pm

I think this could be a very important topic. Many cruiser riders secetly crave apes but don't really have the knowhow to do it. Watch this space
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Mr Intruder
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Sun Aug 19, 2012 10:51 pm

Thanks for the positive comments guys & John thats the reason that I will go into so much detail

Crash I am not sure when I will have them finally finished, as we are temporarily down to one car at the moment & I am using the bike everyday for work but hopefully not too long. I will add the extended brake hose I had made in the week some time and hopefully get around to making up the throttle cables next weekend. When I have done that I will probably get around to extending the wires and adding the apes.
Lack of time is my issue & I can't risk the bike not being available for work so a short and relatively easy job is becoming very drawn out.
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alfie92
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Wed Aug 22, 2012 10:19 pm

Hi Dave cheers to yourself and Freemo,have just done the mod to the clutch cable,makes the VL800 bars better with the cable going to the front of the tree,"were it should be".

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Mr Intruder
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PostSubject: Re: * 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*   Thu Aug 23, 2012 7:18 am

No worries Alfie, always good to share idea's
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* 9" Clutch Cable Modification For Use With Apes on Suzuki C800 / C50*
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