Just thought you guys may want to see how the cables should be routed. I tried the suggested routing but still was not happy.....
Stock cable ? Just got my 610 yesterday. Feels like the cable is binding or rubbing against a sleeve. Right now the cable is running behing the bars but I suspect it should run over the bars. I've heard a lot of guys breaking the stock cable AND the Barnett cable after only a short time. Surely that must be preventable.
The stock clutch cable is rather short and should run behind (toward the rider) the bars AND the risers. The Barnett is long enough so that you can run it under the bar and between the risers. The end that attaches at the lever is the biggest weakness in the Barnett cable. If you have one, keep the end lubed where it mounts within the lever. Also, check to see that the lower cable end is properly aligned so that the travel of the clutch actuation lever on the engine case does not cause the wires of the cable to rub against the cable sleeve.
Boatman, this is a very clean and professional looking set up. What headlight are you using (still stock?) and how could one get this same setup like you have as far as the parts. It looks like you may have done all the surgical work yourself. If so, do you have any left overs?
Tidy! One of my projects for the winter is to rewire the 630. There's so much stuff which is either unused (indicators) or can be repositioned (lambda sensor bypass) to try and tidy it up. Not least that the cabling coming between the fork stanchion and the headstock is fat enough that it gets a little squashed on full lock.
