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Question DT400B clutch cable too short

  • Jammyyammy
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DT400B clutch cable too short was created by Jammyyammy

A while back, I bought a repro (Arghh!!!) clutch cable for my DT400B Twin shock, US import and have now discovered it’s too short. It’s a ‘hi level’ 428755. I’ve searched my records and I can’t find out where I bought it from, which is slightly annoying. It’s probably a good 6 months since I bought it. Can anyone recommend a UK supplier that sells ones of the correct length, so I don’t do the same thing again, which would be more annoying.

update…. My message above failed to send.
I’ve just ordered one from Brooksbarnparts (uk eBay seller). I’ll post a further update to let you know how I get on.

 
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Last edit: 04 Dec 2021 11:07 by Jammyyammy.
29 Nov 2021 14:27 #1

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Replied by Jammyyammy on topic DT400B clutch cable too short

The repro clutch cable from brooksbarnparts is too short as well!
Arghhhh!
Am I doing something wrong?
The cable routing is via the hole under the ignition switch - which is where I’m sure the original one went.
See photo - I’ve lined up the original and the two repro (not OEM) ones that I’ve bought from different sellers on eBay, both marketed as suitable for DT400B.  There is a difference of approx 60mm / 2.5inches.
Before I go for a third attempt, can anyone offer advice on where to buy one from (uk please)…


  

 
Last edit: 04 Dec 2021 09:51 by Jammyyammy.
04 Dec 2021 09:01 #2

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Replied by Jammyyammy on topic DT400B clutch cable too short

Sorry my posts are so boring. Hopefully they will be more entertaining if I ever get this bike on the road…




 
Last edit: 04 Dec 2021 10:19 by Jammyyammy.
04 Dec 2021 10:18 #3

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Replied by Gr8uncleal on topic DT400B clutch cable too short

Handlebars standard size?

Cable routed from where you have it and then alongside the left frame tube and to the actuator/lever on the underside of the engine.

If you haven't done so already, check out the Service Manual in the Tech Library - at the back is a comprehensive cable and routing diagram.
04 Dec 2021 12:04 #4

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Replied by Jammyyammy on topic DT400B clutch cable too short

Yes, standard bars. I’ve double-checked the routing. Nothing left now other than try different suppliers until one fits.
04 Dec 2021 13:55 #5

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Replied by Sneezles61 on topic DT400B clutch cable too short

How about finding a cable making setup? If just the cable is bad, but the housing is good... Just an idea to ease the frustration..
Sneezles61
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04 Dec 2021 14:42 #6

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Replied by MarkT on topic DT400B clutch cable too short

I think someone in the UK had this issue a while back...  the theory was they are selling the DT400MX cable as the same part as the DT400 twin shock...

DT400 twin shock cable is under the engine and needs to be longer.  Sounded like UK suppliers think they are the same?

I seem to remember the person with the issue saying that made sense and that he was getting an OEM one someplace (probably US ebay?)  I don't recall that any more was said... I tried to find the thread but couldn't.  It might be mixed into a restoration or some other topic. 
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
04 Dec 2021 20:02 #7

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Replied by Jammyyammy on topic DT400B clutch cable too short

Thanks MarkT - I found the old thread where there was a similar issue (from Keith R). I contacted him and he kindly looked for the eBay seller who he bought from but they are no longer listed.
Thanks Sneezles61 - I never thought of that. My outer cable is fine, it’s just the nipple (handlebar end) is badly worn, so I could buy a universal inner wire with a mechanical fixing on the lower end. I wouldn’t trust myself to solder one on - and it is out of sight. Can anyone recommend a uk seller??? I’ve noticed some of the nipples (handlebar end) are just a circular barrel of metal and some have an additional crescent of plastic. 
Other than that, it’s remortgage the house (again) for an OEM NOS cable..
Last edit: 05 Dec 2021 01:14 by Jammyyammy.
05 Dec 2021 00:31 #8

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Replied by Pete-RT1 on topic DT400B clutch cable too short

Phil, might be worth contacting these guys and have just the inner cable replaced on your existing one.
I haven't used them, just found them via Google.
www.carrotcycles.co.uk/custom-made-cables.html
Yamaha RT-1
Yamaha CT1-B
Yamaha CT1-C
Yamaha AT1-C
Yamaha CT3
05 Dec 2021 04:02 #9

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Replied by MarkT on topic DT400B clutch cable too short

I just checked and the cable appears to still be available from Yamaha?  CMSNL appears to have them in stock.  www.cmsnl.com/yamaha-dt400-1975-usa_mode...reclutch_3632633503/

Not sure what your time and all the hassle and cables that don't fit is worth to you...  but might just be cheaper to get the right part from Yamaha?  A local dealer might have or be able to get one...  no reason they shouldn't be able to. 

 
1963 YG1-T, 1965 MG1-T, Allstate 250, 1970 CT1b, 1971 R5, 1973 AT3MX, 1974 TS400L, 1975 RD350, 1976 DT175C, 1976 Husqvarna 250CR, 1981 DT175G, 1988 DT50, 1990 "Super" DT50, 1991 RT180, 2017 XT250
Last edit: 05 Dec 2021 08:05 by MarkT.
05 Dec 2021 06:06 #10

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