clutch cable melting

[mtrombla08]

i have a problem. I have went through three clutch cables in one year. The problem is they melt where the cable runs through the headpipes. Is this a common problem? Has anyone else had this and maybe found a solution?

[CJM]

Run the cable another way or wrap some heat insulating stuff on it.

Me, I did that once and ran the cable around it and put heat flashing tape on it just incase.

[fishnfergie]

I believe people use the TRX90 clutch cable because it is longer and able to be re routed. Im not 100% sure if its the 90 or not but one of them is longer and able to be run along the frame...

[NacsMXer]

Originally posted by fishnfergie
I believe people use the TRX90 clutch cable because it is longer and able to be re routed. Im not 100% sure if its the 90 or not but one of them is longer and able to be run along the frame...

Doesn't the TRX90 have an automatic clutch?

Maybe you are thinking of the 250X. Anyway, get a clutch cable for a 92 250X, Honda part# 22870-HC0-670. It is longer so you can route it down the side of the frame instead of through the headers.

[mtrombla08]

ok thanks guys. i figured there was some bike with a longer cable i just didnt know what one.

[300ex_Kid21]

iv had the same problem. just tonight i put some conduit on it where it melts and electrical taped it in place. dont know how its gonna work but ill let ya know.

[fishnfergie]

Yup Sorry I meant the 250x!

[ian0615]

re route that thing and zip tie...I thought i had a leak in my pipe..come to find out my cable was on fire!! haha anyways..zip tie i love those things!!

[logant14]

i tried putting a 250x cable on mine and it was to long any ideas?

[CJM]

Originally posted by logant14
i tried putting a 250x cable on mine and it was to long any ideas?

Did you run it along the frame instead of the original route?

[logant14]

yes i even tried wrapping it around the frame to shorten the lenght

[Built_300EX]

Here is the fix.
When running the stock 400ex cable. That black bracket that is infront near the gas tank. Instead of running your cable through that, run it on the outside, once you tighten the cable up at the motor and the clutch perch. You can move it around outside that bracket and pull any tension up from the headers, get it perfect until you have it set correctly.

Take a ziptie after pull the slack from the cable and have it perfect, pull it tight. Your cable will actually stay and not burn.

Also for safety, I threw on some heat tape around the cable that was close to the header.

After the zip tie, the heat tape hasnt been touched. Cable feels great, no burning smell. All good to go.