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clutch cable breaking !!!

  • Thread starter Thread starter xDUKEx
  • Start date Start date
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xDUKEx

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ok guys does anybody else have problems with breaking clutch cables. I seem to go thru at least one every year ??? if yes does anyone know how to fix this problem ??? they allways break right where they connect to the lever on me !!!
 
yep. I replaced mine with one from an 850, it has a little teflon sleeve and a smaller knob on the end. the teflon lets it slip nicely and it doesn't have to bend the wire as it steps around. also try checking the lever to make sure there's no burr inside catching the ball end, they are typically lead and will get caught on anything...

I've also heard the OEM are much better than the aftermarket...
 
A clutch cable is usually good for me for 2 or 3 riding seasons, and then I replace them whether they need to or not. I use stock Suzuki items.

I lube them every couple of months, which helps the action. A dab of grease at the lever end does the trick as well.

A clutch cable should not go bad after just one year. Check your routing and any other obstacle.
 
xDUKEx said:
ok guys does anybody else have problems with breaking clutch cables. I seem to go thru at least one every year ??? if yes does anyone know how to fix this problem ??? they allways break right where they connect to the lever on me !!!
Click to expand...

I'm still using the original clutch cable that came on my bike when it was new in 1980. If you are using replacement cables that are equal to OEM quality, I would check the operation of the lever to see why it is putting stress on the cable. If the cable end is not rotating freely, it may be causing the inner cable to bend when the lever is pulled. If the inner cable is bending, it will eventually have stress failure at the lever.
 
bought a wrap-a-round cable luber from the chapperal dirt bike supply catalog 20 years ago. Lube the cables with BG cable lube at the end of each riding season. I also put white lithium grease on the ball ends when I reassemble. I've broken a clutch cable twice in 20 years and over 500,000 miles using this regiment. Never have lost a throttle cable.
just my $.02 ....jack
 
You might want to check the adjusting sleeve on the lever mount. My Brother was going through clutch cables frequently and after replacement, I noticed his adjustment sleave was grooved and sharpened on the end. Replaced adjuster, end of problem.
 
the little teflon sleev seams to fix it. the problem might be caused by and ege shaped socket where the let ball fits into the handle
 
I've used an aftermarket clutch cable for well over 40,000 miles with no problems -- the Suzuki OEM cables don't cost much more, so use what makes you feel comfortable.

My original clutch cable broke because the hole in the lever where the cable end sits had worn slightly egg-shaped (yes, it had the plastic on it) and it was binding enough to stress the wires.

So you might also need to replace your clutch lever. It's also rather inexpensive, fortunately. The aftermarket levers seem to function well enough, but the Suzuki levers are noticeably better quality and the finish (on later models with black levers) holds up much better.

Also, there were some good hints earlier about checking the adjuster and the lever perch for grooves, wear, and sharp edges in general. All these parts are fairly inexpensive.

You'll find that the controls are much easier to use and have a much better feel with a little yearly attention to these details. Smoother, more predictable controls lead directly to the ability to ride smoother, faster, and more safely.
 
I was going through OE Suzuki clutch cables pretty regular. Up at the lever like you indicated. Little Teflon thingy in place, well lubed and properly adjusted. I looked at things, i filed and debured, etc. Got so i would just carry a spare. And then......realized this problem may have to do with the clutch disks and "stiffer clutch springs" i had put in prior to having replaced any clutch cable ever.

I removed the "new" springs, and put in the original springs that came out. (i never throw out anything, even have broken clutch cables, they still have shinny parts?) I now have extra new spare clutch cables. Don't seem to need them any more. The springs weren't racing springs or anything. HAd a little disclaimer next to them when i bought the discs and springs from bikebandit. said something about these springs being stiffer than the originals. I got hands that can crush a sealed can of beer, so little stiffer didn't bother me none!
 
chef1366 said:
Dang Philip, you can suck every inch of life out of things.:-D
Click to expand...

Yeah, I know, I know! I will tempt fate again by revealing my good fortune.:)

Original R/R, stator, petcock, clutch, all cables including speedometer & tachometer, & seat cover. I don't even remember having to replace a headlight bulb, although I replaced one with a Osram Silverstar as an upgrade. Never had a flat on this bike (since 1980). I have some mostly new replacements in case I should need one.

I did have to replace a burned out license plate bulb recently, though.:-D

My daughter has invited me to dinner tomorrow night. There is a hard freeze of about 23? expected tonight and a high of 34?F tomorrow, changing to freezing rain early Thursday. The local weather has had the most rain in 30 years. To get to her place and back, I have to negotiate an inclined narrow mud/gravel track through slippery grass & mud (my 600 ft. driveway), tight curves, a long steep hill (about 500 ft. elevation change) with more curves, then a country road 'till I hit a very curvy road that follows the Clackamas river for about 12 miles until I start getting to straight roads that are less likely to be icy. The distance is about 55 miles round trip, and I am keenly aware that one mishap could change my good fortune to disaster.

(pardon the hijack)
 
Hey boondocks
you mean...your gonna take the bike?
errrrr, is this daughter available??? sounds like a good place to live.
 
nert said:
Hey boondocks
you mean...your gonna take the bike?
Click to expand...

Always. I went riding today in 35?F weather. Cars are too dangerous.:wink:

errrrr, is this daughter available??? sounds like a good place to live.
Click to expand...

Sure, she's available ... to her husband.:-D

Oregon is full of beautiful and scenic rides, from ocean to forests to volcanic mountains to rolling hills to desert.
 
All this talk about broken clutch cables makes me downright nostalgic for the hydraulic clutch on my '85 Shadow.....
 
There are basically only two things to consider

1- Cable routing. If you have kinks and twists, the cable will bind.

2-Full lubrication. Let oil drip through the cable until it runs out the other end, or use a nozzle that permits oil to be forced into the sheath.



If you want the most strength, keep the sheath and make your own cable, using galvanized aircraft wire/cable. !/16 inch cable will let you pick up the entire bike and shake it, which makes a good show for the women, and builds strong wrists. :)
 
Boondocks said:
Yeah, I know, I know! I will tempt fate again by revealing my good fortune.:)

Original R/R, stator, petcock, clutch, all cables including speedometer & tachometer, & seat cover. I don't even remember having to replace a headlight bulb, although I replaced one with a Osram Silverstar as an upgrade. Never had a flat on this bike (since 1980). I have some mostly new replacements in case I should need one.
Click to expand...
You're screwed now buddy!


I know you have lots of wood up there to knock on!
 
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