66 CA77 Clutch Cable Issue

pwilke1 · Post by **pwilke1** » Mon Apr 26, 2010 2:13 pm

I'm having trouble tracking down the correct size clutch cable for my bike. Previously I've ordered a CA77 clutch cable from a vendor measuring 53" but realized it was too long when attempting an install. I have a 66 CA77 Honda Dream. Model number CA77E-1012625. However the clutch cable I'm replacing measures approximately 40". I'm a bit confused on why mine would be so short? Any ideas? I found a clutch cable on Apex Cycles but was also told it was 53". Thanks in advance.

-Patrick

brewsky · Post by **brewsky** » Mon Apr 26, 2010 2:46 pm

The cable I removed form my '66 measures 44" tip to tip of the cable and 41" sheath length (including the metal bend at the lever end).
I too ended up with a replacement that was too long and without the metal bend, and will eventually find another or shorten the new one.
I have seen some on e-bay occasionally of the correct length.
The longer one will work, but you have to make a couple extra bends and that increases the pull effort somewhat.

pwilke1 · Post by **pwilke1** » Mon Apr 26, 2010 2:54 pm

To the best of my knowledge most things on my bike are stock. However could the shortened cable length be caused by aftermarket handle bars? I've attached an image of my dream for reference. I'll have to check around on eBay.

brewsky · Post by **brewsky** » Mon Apr 26, 2010 4:03 pm

Looks the same as mine as far as I can tell.
You might check around some of the older motorcycle shops near you, as they may be able to shorten your new cable to the correct length.

pwilke1 · Post by **pwilke1** » Mon Apr 26, 2010 4:46 pm

That was actually my next move. Thanks for the advise!

-Patrick

pwilke1 · Post by **pwilke1** » Tue Apr 27, 2010 2:30 pm

After calling around the local shops, I still haven't found anyone to adjust/shorten the cable. One suggestion was to put a loose loop in it. Could this affect function? I have also seen on several post where shorter clutch cables pop up on eBay but no luck so far. I did however find a shop who knew somewhere that could fabricate a new cable using my dimensions but the turn around time was 6 weeks. What about using a universal cable?

Side note, the cable I may be installing installing does not have the chrome covers leading up to the handle bars. Any idea if there is an aftermarket solution to this? I found some Spring-type Chrome Cable Covering on this site : http://www.scootworks.com/shop.cgi/page ... T_SID_HERE ,but wasn't sure if this would be similar enough.

Thanks in advance!

-Patrick

rpr851r · Post by **rpr851r** » Tue Apr 27, 2010 3:10 pm

I feel your frustration. You may want to consider Motion Pro. Their stated turn around on a custom cable is 5-7 days. You can also see if there are any custom bike builders in your area. They are more likely to have the pieces and expertise to shorten the cable you have than a dealer. It’s not hard to do but if not done right the ends pull out through the barrels.

http://www.motionpro.com/custom/index.php