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Last night I was trying to install my Motion Pro clutch cable replacement and ran into some fitment problems. It appears to be about three inches shorter than the one it came with. I have no idea if the one I was replacing is OEM, but it was plenty long. When I tried to run the new one, it came up short. I bought the online manual, but it doesn't show the correct route for the cable. My KDX has higher handlebars, but surely that doesn't make THAT much difference. I checked the part number and it is correct for a '95 KDX 200.

Any suggestions and/or does anyone have a diagram of the correct routing for the clutch cable? Gracias.

The cable routing is shown in the Kawasaki manual.

Slick_Nick wrote:The cable routing is shown in the Kawasaki manual.

That would be helpful if it was the "online" manual. Don't have the old school version.

I mean, I've got the kawi manual in both hard copy and digital PDF format. I'd post up the page you need, but the powers that be here will probably just end up deleting the post because it's "copyrighted material".

The online manual is terrible, try and procure yourself a Kawasaki one.

Since you have altered the design by adding higher bars, you might want to remove the tank, and headlight and do some experimenting with the routing. It usually is not rocket science, but it can make a difference if your cable length is barely long enough. Make sure you observe/inspect the cable routing closely as you turn the bars lock to lock to make sure that the cable is not getting pinched or pulled by other items.

gregp wrote:Since you have altered the design by adding higher bars, you might want to remove the tank, and headlight and do some experimenting with the routing. It usually is not rocket science, but it can make a difference if your cable length is barely long enough. Make sure you observe/inspect the cable routing closely as you turn the bars lock to lock to make sure that the cable is not getting pinched or pulled by other items.

That's good advice, right thar.

Did you put it side by side with your old one?

There's no way mine would ever fit even if it were half an inch to short

gregp wrote:Since you have altered the design by adding higher bars, you might want to remove the tank, and headlight and do some experimenting with the routing. It usually is not rocket science, but it can make a difference if your cable length is barely long enough. Make sure you observe/inspect the cable routing closely as you turn the bars lock to lock to make sure that the cable is not getting pinched or pulled by other items.

Being it came with the bars, I just ordered the replacement that was listed. Might not have been a good idea. I will do as you have suggested and see if the route can be improved. I believe it can.

Thanks!

Mr. Wibbens wrote:Did you put it side by side with your old one?

There's no way mine would ever fit even if it were half an inch to short

Yeah, after I had installed it and observed it was short! lol

Got it on today. It could not be ANY shorter and still work though. It is getting stretched to max when the bar is all the way to the stop. But it's on and adjusted though.

That doesn't sound right... Mine can go stop to stop and have several inches left over.

Slick_Nick wrote:That doesn't sound right... Mine can go stop to stop and have several inches left over.

I have higher bars than stock. Apparently much higher (they came with it)

Okay, the maker of the cable is important. I found that the Motion Pro cable is 38.25" (sleeve) with an overall length of 42.25". The Parts Unlimited replacement cable is 42" with an overall length of 44.5". Mental note of that extra length if you have higher bars.

I've got a motion pro cable and 2" bar risers

If I ever have it off the bike I'll measure it