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Like a complete and utter idiot I pulled the clutch outer housing without attaching a new outter to the end. I would have thought there was an opening in the frame but apparently that's not a thing. Has anyone succeeded in routing a new clutch cable through the frame and up the headset without loosing there mind?? Thanks in advance.
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Not to fear, there is a way.

I would not go from bottom up, but rather top of headset down.

In a case like this, I'd take the gas tank out so then you can see inside the frame. Then take the horn out. I then just push the new outer down the steering tube opening while guiding it into the bottom of the frame from access through the horn opening. While pushing the outer down from the top, put your other hand through the frame opening (gas tank opening) to get the end of the outer over the steel ridge inside the frame.

Once it's over that ridge, it can be pulled through out the hole in the back of the frame.
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^^ this.

pull the speedo, loosen the headset, pull the horn and tank and you should be able to shimmy shake it in there. it's gonna be tedious but it can be done.

i've also resorted to using a length of fish tape to wind my way thru as well. just another option.

-g
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Thank you and thank you again!!! I'll report back asap
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What Nomad & Greasy said.

And if you don't have a suitably small fish tape, you can probably use a length of nylon cord for a weed whacker to work your way through, too.
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or another inner cable fed through first as a new feeder which you can slip the outer over and pull back through frame.
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Doin your time
hardest bit is often as it tries to bend around the horn area..at this point I also rotate the outer cable as well as push or pull. Or a long piece of strong wire threaded down from the top..if its thick enough it will push the other cables aside rather than bend
Its all part of being a scooterist and "doin time "on cables is the price you pay
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Thinking out of the box here, guys...
Buy a long roll of thin picture hanging wire.
Cut two lengths 3x the length of the cable.
Pull the inner out of one of the shifter cables.
Run the two lengths through that outer.
Pull out the shifter cable with the two wires in it.
All I got so far.
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Ray8 wrote:
Thinking out of the box here, guys...
Buy a long roll of thin picture hanging wire.
Cut two lengths 3x the length of the cable.
Pull the inner out of one of the shifter cables.
Run the two lengths through that outer.
Pull out the shifter cable with the two wires in it.
All I got so far.
He already pulled the inner and outer out.
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areabaylove wrote:
Like a complete and utter idiot I.....
I can't remember how many times I've said this working on these things.
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nomadinsiam wrote:
Not to fear, there is a way.

I would not go from bottom up, but rather top of headset down.

In a case like this, I'd take the gas tank out so then you can see inside the frame. Then take the horn out. I then just push the new outer down the steering tube opening while guiding it into the bottom of the frame from access through the horn opening. While pushing the outer down from the top, put your other hand through the frame opening (gas tank opening) to get the end of the outer over the steel ridge inside the frame.

Once it's over that ridge, it can be pulled through out the hole in the back of the frame.
When I was pulling a few new wires through the frame this is how I got them through also, removed tank and anything else I could for access. A bit different on the routing as I stuck my fish tape though the top and pulled the wiring from the gas tank side but same idea. A fish tape has a round end instead of blunt end end will slide over metal ridges instead of hitting one and stopping.
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nomadinsiam wrote:
Ray8 wrote:
Thinking out of the box here, guys...
Buy a long roll of thin picture hanging wire.
Cut two lengths 3x the length of the cable.
Pull the inner out of one of the shifter cables.
Run the two lengths through that outer.
Pull out the shifter cable with the two wires in it.
All I got so far.
He already pulled the inner and outer out.
I'm saying to "borrow" one of the shifter outers to pull two wires through. If two wires don't fit, one can go though with two tied to the end before pulling the outer. That will leave you with two wires to pull both the borrowed outer and a clutch outer back through. Use solid wire.
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Ray8 wrote:
I'm saying to "borrow" one of the shifter outers to pull two wires through. If two wires don't fit, one can go though with two tied to the end before pulling the outer. That will leave you with two wires to pull both the borrowed outer and a clutch outer back through. Use solid wire.
This will only work is the shifter cables have already been replaced at some point. Vespa clamped the shifter cables together at the factory.
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Ray8 wrote:
nomadinsiam wrote:
Ray8 wrote:
Thinking out of the box here, guys...
Buy a long roll of thin picture hanging wire.
Cut two lengths 3x the length of the cable.
Pull the inner out of one of the shifter cables.
Run the two lengths through that outer.
Pull out the shifter cable with the two wires in it.
All I got so far.
He already pulled the inner and outer out.
I'm saying to "borrow" one of the shifter outers to pull two wires through. If two wires don't fit, one can go though with two tied to the end before pulling the outer. That will leave you with two wires to pull both the borrowed outer and a clutch outer back through. Use solid wire.
I don't know what that means. It's really not that hard to feed a clutch outer housing through if the gas tank is already out.
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Yep most times it's easy to do it the hard/long way by pulling gas tank and headset, worse case scenario you can use one of the throttle cables to pull a line through. Shifter cable is another option but we all know what adjusting a shifter cable is like for us rookies.
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Lynnb wrote:
Yep most times it's easy to do it the hard/long way...
Haha!😅

Taking the tank out ain't that hard, and it simplifies the operation immensely.
⚠️ Last edited by nomadinsiam on UTC; edited 1 time
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Not when you've done it 20 times trying to fix a leaky fuel tap, not so much when it's your first time. However, taking it out is the easy part, it's getting it back in that's slightly tricky.
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Ok, makes sense.
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Okay, just did a variation of my previously crazy idea. Super pleased.
Destroyed two shifter outers and one of the cables completely while drilling a hole to run CHT/tach wires. Left with one damaged but just-has-enough cable.
Soldered two 20lb, 10 ft long steel wires to said cable at the shifter end. Could have soldered 3 easy.
Sorry, camera focused on the splooge on the floor
Sorry, camera focused on the splooge on the floor
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Pulled battered cable and outer up through the headset, along with the 2 fresh wires.
Slid two outers over the wire lengths left (about 5 feet) at the shifter end. Tied em up solid at the ends (photo).
They pulled up like butter. No, really. Butter.
With 3 wires, one could replace all three (2 shifters and clutch) outers, in a pinch like mine.
Forum member supplied image with no explanatory text
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