The Hodaka Club Forum

What is it with these Toad clutch covers that they keep breaking apart at the threaded area where the clutch cable screws in? Went to disconnect the cable to pull the motor out, and a piece of the cable holder just fell of into my hand! Had to buy yet another cover..... Victor

Never had this happen on any of my Hodaka’s

Same here - I've SEEN exactly one clutch case with a broken clutch cable adjuster boss, but have never experienced one on any of my bikes.
Ed

I see them constantly on eBay with broken bosses. Sometimes you have to sift through the offerings to make sure the bosses aren’t broken off. But I guess that’s just my experience.

The boss on this cover just seemed to fall apart in my hand while unscrewing the cable adjuster. Victor

use a smaller hammer. just joking Clarence

The only thing I was using was a 10 mm open end wrench, and a small one at that! Victor

Victor, where on the boss is it breaking? Is the entire boss falling off of the case?

Was all the tension off of the cable? Was it a new clean brake or a corroded old crack? -----------Clarence

Usually it's the outside arm that breaks off, more or less parallel to the rear of the cable slot. I have several like that.

I took a look at my stash and in fact have one as you describe, Thrown. Seems like it would be a tough repair. Has anyone performed such a repair and if so, how?

I would imagine welding, machineing and threading.

I'm going to take a closer look at mine to see how much metal there is to work with at that spot.

Gremlins! My Gremlin likes to pull up the Rivet holding in the Clutch Arm. I have 7 spare Outer Clutch covers and 2 have Rivets that are working loose. Can`t happen? My Super Rat was 2 weeks old when it happened the first time. Looking back on it, I think that it just wasn`t seated all the way at the factory. You know what Victor, Just buy another cover. If that one breaks too you did something sinister when you were a little kid and the powers that be have hexed you. You may need to consult a Voodoo Mama to end this problem once and for all! More than likely a Chicken Foot tied to the Cable near the Cover should do the trick! Just trying to help. A little levity! Sure can`t hurt! Joe.

Nothing sinister done, Joe, and I bought a replacement cover before I posted this thread. No getting around it. $40 for another case before the bike has even been ridden! Wish I knew how to Tig weld aluminum. I see so many of these covers on eBay with broken bosses, that you really do have to be careful & check the pictures carefully! No one posts one for sale and specifies “This has a broken clutch cable boss.” Victor

Case in point

Extreme broken

That’s almost exactly how mine broke. And all I did was turn the screw. Victor

I have a pile of old Ace and Wombat clutch cables where the lower adjuster on the cable itself is broken in half, but never had an ACE or Wombat clutch cover with the threaded boss broken off. I believe when they made the cable end bigger and stronger on the oil injected models to fix this, they transferred the problem to the case boss, which had to be cast thinner to allow for the bigger thread of the "new and improved" cable. Seems they broke one thing while trying to fix another.

The first and third pics are Ace covers, the middle one is off a Wombat.