Clutch pedal

I bought a new 8mm solderless nipple for the end of the clutch cable as the first one came loose some weeks ago.  The new one has a grub screw with a point as opposed to just a bolt that the last one had which should hold the cable better.

I decided to solder the end on as well as clamping it with the grub screw.  To do this I pulled the cable through, frayed the ends slightly, applied some flux, pulled the cable back into the nipple, tightened it and soldered it.  When soldering I heated the nipple directly, not the cable as I didn’t want to damage the cable.  Once the flux was boiling I applied the silver solder and it ran into the nipple and filled around the cable.  The excess cable was then cut flush with the dremel.

Next I installed the adjusters to the sprocket cover and to the bulkhead, cut the outer part to length and threaded that onto the cable.  I then held the pedal in position to determine where on the cable the clevis would be fixed.  The clevis is held in position by two grub screws to which I applied Loctite.  I also doubled the cable back on itself and fixed it with a cable clamp just to be sure it wouldn’t come loose.

I also installed front and back cable stops, exactly the same as with the throttle pedal.