I have a dilemna, I'll give a little background. About 5 years ago I broke a clutch cable. I put a new one on the bike and rode some more(stock perch and lever) then let my bike set up for about 4 1/2 years since. While it set up I put all new plastic, ASV pro model c/5 clutch lever and perch with the quick adjust on it. The bike is a 99 CR 250. When I went to hook the clutch cable up to the new asv perch/lever, I had to pull up the clutch arm inside the cover to get the cable to reach. This wont work, the cable is pulled tight therefore eliminating the necessary slack/play between the clutch lever and the perch. I thought, damn, maybe they sent me the wrong cable. So I ordered a new motion pro cable from motosport.com and got it, took the other cable off and they are the same length. So put the new on the bike and same thing. Have to pull the clutch arm up to get the cable on it, and it still doesn't go all the way back down so there is still no slack.......I called asv and talked to a tech the other day, he said they've never run into that problem and I may have to get a custom length cable....I don't see how this is, as the quick adjust should add an extra length requirement the cables length as far as my brain can figure. Since the stock lever doesn't have this...I took the quick adjust knob and the normal thumb adjust thing that screws into the knob off and let the cable housing go directly into the perch and now it's long enough but looks kinda crappy...I don't see how others dont run into this problem since the quick adjust seems like would always require a longer cable to make up for the extra distance it adds between the perch and the end of the cable housing. Hope this makes sense to somebody and they can explain what the deal is.......It's running me crazy!!!! Thanks!!

Check the end of the cable that's inside the ignition cover, sometimes the part that the cable attaches to on that end can get out of position and bind up.

Best to put the lever side on first, then the engine side. At least it was easier for me on my 125.

checked that again, it is fine. also my new idea of taking the quick adjust off is not gonna work. I was messing with it some more and pulling the clutch lever and it pulled the end of the cable all the way through the perch. I thought it had a lip in the perch that wouldnt let it come all the way through but it dont. So this isnt gonna work....There's no way possible this cable is gonna work with this perch unless there is some kind of adjustment inside the clutch side of the engine that will let me adjust the height of the clutch arm on the ignition side......the arm itself is just too low for the length of the stock cable with the asv lever while the quick adjust knob is on there.......I just can't understand......wish I could find my stock clutch perch and lever!!!! I think I accidentally threw it away.

I just bought the motion pro cable and the f3 pro cllutch and brake levers and all I had to do was adjust the cable length. that part of the cable may need to be adjusted on the cable. Is your cable all the way up to the perch, cause I gave mine about .5" play onthe fly adjust.

yeah the cable goes down into the top of the ignition part and seats into the hole with an o ring to seal it off so that end is all the way in, on the perch end, with the adjustment stuff taken off, the end of the cable housing goes all the way to the hole in the perch, where the adjustment knob would normally mount, for the end of the cable to reach the hole/slot in the lever itself. so ANY extra length added by putting the knob back on, keeps the end of the cable from reaching the hole in the lever........impossible for this to work with the adjuster added back to the perch unless there is an adjustment inside the clutch side of the engine that will make the clutch arm possible to move up toward the carb. I may need to take pics to show what i'm talkin about?? oh yeah, and the inline cable adjustment has been adjusted every way possible. since the cable is too short with the quick adjust knob on the perch, the inline would have to be screwed all the way toward the engine. there is no adjusting that can fix this problem, gonna have to have a longer cable if i cant adjust something inside the clutch cover itself..this is running me crazy lol I can't understand how this is happening

there is an adjustment on the cable itself.. You should loosen the nut and turn that adjustment all the way in.. so no threads are showing.

yeah, it's all the way in, still about a half inch too short to reach the arm inside the ignition cover. I've looked at schematics on honda of troy website and see no adjustments for the clutch arm. only way I can get the cable on the clutch arm with the quick adjust on the perch is to pull that clutch arm up about half inch and put the end of the cable into it, then the arm wont go all the way down like its supposed to cause the cable is too short . I'm stumped........

\TRIPLE POST SOMEHOW.......

TRIPLE POST SOMEHOW.....

still no luck............any more ideas?? This HAS to be a model specific problem......the cable must be on the verge of being too short with the stock perch for the adjuster on the c/5 to make it too short......could routing be a problem? I'm pretty sure I routed it the same as the stock cable. Don't think that could matter anyway...