Clutch Cable Measurement?
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  1. #1
    Senior Member SpudRider's Avatar
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    After riding 49,000 miles, I need to replace the clutch cable on my Zongshen 200GY-2, a Chinese copy of the TW200. I am ordering some aftermarket parts on Monday, and I would like also to order a TW200 clutch cable. I'm sure the length and the connector at the engine side of the TW200 clutch cable are correct for my Zong. However, I would like to confirm the nub at the lever end of the clutch cable is the proper diameter for my Zong's lever. Can someone please tell me the diameter of the metal nub of the TW200 clutch cable which fits into the circular slot on the clutch lever? Thank you.



    Spud
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  2. #2
    Senior Member TW-Brian's Avatar
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    Hey Spud,



    I didn't take the cable end out but the circular opening in the clutch lever measures about 0.34".



    Brian

  3. #3
    Senior Member SpudRider's Avatar
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    Quote Originally Posted by TW-Brian View Post
    Hey Spud,



    I didn't take the cable end out but the circular opening in the clutch lever measures about 0.34".



    Brian
    Thank you, Brian. I calculate your measurement at a little over 8mm, or 5/16-inch. Is that correct?







    Spud
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  5. #4
    Senior Member Gerry's Avatar
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    Kind of had my bike out doing some stuff. The handlebar lever end of the cable is indeed 8mm. Seems the crimped 'barrel' end has a rotatable metal sleeve over it, likely to afford a smoother swivel and minimize wear to the aluminium lever housing. Yes again to the 8mm total diameter. 49,000 miles ? I thought you had a business to run. Seems you have an awful lot of 'playtime' on your hands. Good to hear from you Spud.. Take care. Gerry
    Take care my Friend.........

  6. #5
    Senior Member SpudRider's Avatar
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    Quote Originally Posted by mrgizmow View Post
    Kind of had my bike out doing some stuff. The handlebar lever end of the cable is indeed 8mm. Seems the crimped 'barrel' end has a rotatable metal sleeve over it, likely to afford a smoother swivel and minimize wear to the aluminium lever housing. Yes again to the 8mm total diameter. 49,000 miles ? I thought you had a business to run. Seems you have an awful lot of 'playtime' on your hands. Good to hear from you Spud.. Take care. Gerry
    Thank you, Jerry. It's always good to hear from you, and the other friendly members of this forum. It appears the TW200 clutch cable will be a perfect fit for my Zongshen 200GY-2; I'm going to order one on Monday.







    Spud
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  7. #6
    Senior Member SpudRider's Avatar
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    My best friend gave me an old, XT200 clutch cable, so I installed it on my bike. However, the XT200 clutch cable has a knob on the end which inserts into the 8mm barrel. This knob extends slightly down the cable, and increases its diameter. Therefore, I needed to modify an old clutch lever by widening the cable slot in order to make the XT200 clutch cable fit.



    The XT200 clutch cable will work for me until I find a proper replacement. However, I am wondering if the TW200 clutch cable is the same, or different from the XT200 clutch cable in this regard. Is this photograph of the lever end of the TW200 clutch cable correct?







    If this photograph is correct, the TW200 clutch cable is not larger in diameter where it enters the 8mm barrel. Did the clutch cable change from the XT200 to the TW200, or did the cable change for different model years of the TW200? Thanks for you help.



    Spud
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  8. #7
    Senior Member SpudRider's Avatar
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    Here's a photograph of a Motion Pro, 05-0110 clutch cable for the TW200.







    Once again, the cable does not increase in diameter as it enters the 8mm barrel at the lever end of the cable. Therefore, I must surmise the TW200 clutch lever changed from the XT200 clutch lever.



    Spud
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  9. #8
    Senior Member Leisure Time Larry's Avatar
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    What would be the differences/advantages to the Motion Pro cable? Cost seems very similar, so why one over the other?
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  10. #9
    Senior Member SpudRider's Avatar
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    Quote Originally Posted by lrppcer View Post
    What would be the differences/advantages to the Motion Pro cable? Cost seems very similar, so why one over the other?
    Are you referring to the OEM clutch cable? If so, I prefer the Motion Pro cable because I can get it delivered much more quickly than an OEM part.



    Incidentally, I installed the Motion Pro clutch cable, and it is working superbly! Once again, I wish to thank Brian and Jerry for their help.



    Spud
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