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Just as the tooth says, I’m on my 4th clutch cable in the 10 months that I’ve had the bike. At first I thought the first one was just old. I thought the second one was just cheap. After the third one broke I figured out by the third one that it had something to do with the lever because it seems to be catching right where it attaches to the lever, and that’s where it breaks each time.
then I smoothed out what I thought was a burr on the lever and 3D printed a tiny spacer to keep the cable from sawing itself on the edge of the lever. That worked good for a while and I thought I was done with that.
Well, it just broke again.
I read that the levers can wear out over time. Also read that the aftermarket ones are soft junk. Do I need to find new old stock? Or is there a better solution out there?
To be clear, each cable is generously lubed and easy to pull. Before it breaks, I can feel it catching when I pull the lever. And every single one has snapped right where the cable enters the handle.
Update** Upon further investigation it appears the brass bushing in the lever is very worn out, causing a lot of up and down play. I'm not 100% sure that's the issue but it cant be good. I was able to find a new OEM handle. Will try that out and report back. But if anyone has any better ideas, please chime in.
Update # 2: Replaced the handle with a new one. The new handle has almost no play in it, just enough to be smooth but not sloppy at all. And most importantly, the cable does not rub on the edge of the handle or the perch. It sits perfectly in the middle and doesn't touch anything. We will see how this holds up over time.
then I smoothed out what I thought was a burr on the lever and 3D printed a tiny spacer to keep the cable from sawing itself on the edge of the lever. That worked good for a while and I thought I was done with that.
Well, it just broke again.
I read that the levers can wear out over time. Also read that the aftermarket ones are soft junk. Do I need to find new old stock? Or is there a better solution out there?
To be clear, each cable is generously lubed and easy to pull. Before it breaks, I can feel it catching when I pull the lever. And every single one has snapped right where the cable enters the handle.
Update** Upon further investigation it appears the brass bushing in the lever is very worn out, causing a lot of up and down play. I'm not 100% sure that's the issue but it cant be good. I was able to find a new OEM handle. Will try that out and report back. But if anyone has any better ideas, please chime in.
Update # 2: Replaced the handle with a new one. The new handle has almost no play in it, just enough to be smooth but not sloppy at all. And most importantly, the cable does not rub on the edge of the handle or the perch. It sits perfectly in the middle and doesn't touch anything. We will see how this holds up over time.
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