Clutch cable on my RE Himalayan goes bust: How I repaired it myself

January 30, 2025

The locking nut needs to be put inside the lifter arms bracket where usually the clutch cable end pin goes.

BHPian IamAsHter recently shared this with other enthusiasts:

So did a cold start this morning and voila; my clutch cable gave up

Now the task is how to take the motorcycle to the workshop. Was thinking of pushing the motorcycle and putting in 1st gear and continue gear shifts with blips but later dropped the idea.

Now one idea came up, I guess most seasoned riders here use it but I did it for the first time.

I ended up using a locally sourced clutch cable meant for using Bajaj / Piaggio 3-wheelers and it worked wonderfully for rescuing the motorcycle from this situation.

Step 1: Disconnect the clutch cable from the lever end as well as the lifter arm end near the engine case.

Step 2: Hold the cable end at the lifter arm’s end with a plier and pull out the entire inner cable. Make sure that clutch cable outer shell remains as it is in its position, only the inner cable needs to be dragged out

Step 3: Take the new clutch inner cable and push the open end from the lever’s side slowly until the open comes out on the other side.

This inner clutch cables are easily available in any spare parts shop and costs ₹40 max with the cable locking nut included.

Step 4: Use the locking nut to hold the cable at the lifter arms’ end to lock the cable according to the length, the lifter arm needs to be pushed manually to the end where the clutch play ends and clutch engagement starts. The locking nut needs to be put inside the lifter arms bracket where usually the clutch cable end pin goes. The locking nut acts as a cable end pin.

Step 5: Put the starting tip of the cable in the lever slot. For Himalayan’s lever the slot is a bit wide therefore the plastic bracket needs to be inserted though the cable before pushing it through.