Clutch and gearwire service

No way around; the broken clutch adjustment bolt would have to be removed the hard way:

 First by drilling larger and larger hole... First version

 Improved setup... second version. This actually saved the day, without having to dismantle the exhaust.

 Last but not least: refreshing the threads. I actually managed to save the existing threads this way. New clutch wire was installed without further hassle.

Next object of concern: A stubborn gearbox. Inspection of gear shift mechanism revealed...

 ...that nobody ever had adjusted the cables. Tightening the cables did the trick!

Same with the rear brake; adjustment was all that was needed. 

A quick oil change, and voila: Ready for maiden voyage. 

Welcome to the Scooter Sanatorium. "It's easy to get admitted, but one seldom leaves the premises". 

Initial check of the Silver Bullet

Just got the scooter today, and tomorrow we head for Sokndal and Vestlandsrun 2013! Plan was to take the new scoot for a ride. But first: A quick check. First inspection uncovered a gearing and clutch issue.

Clutch and gear needed a check, and as I suspected;

A damaged clutchcable...

Significant slack in the gearing cables will also impair gearing quality... adjustment needed.

Clutch cable wire was dragged out using a bit of force, but fitting a new cable was more difficult than expected. Turns out the adjustment mechanism and clutch cable on the engine side was distorted some way. No other solution than to dismantle.

Have a close look at this picture; during dismantle I managed to break the adjuster while inside casing. The cable sleeve has seen better times, question is whether it can be shortened beyond damage. Alternative is to pull a new cable sleeve, arghh. Time to take a timeout, this will have to be fixed another day. 

This scooter is NOT going to Vestlandsrun 2013.