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Clutch cable snapped after only 1 month

  • Thread starter Thread starter bille
  • Start date Start date
B

bille

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My new clutch cable snapped today, after only 1 month. I have only had the bike a couple of months and I replaced the cable because I thought the clutch was too hard to pull and maybe something was dragging inside the cable. The new cable was just as hard to pull so I figured I just had to live with it.

Until il today when it broke.

What im wonder is if the place where the cable connects to might need to be adjusted? I included a picture of what in taking about but it looks like I can remove this "handle" and put it back on in different positions.

Is is this my problem or is something else screwed up? I ordered a new cable today so I have a few days to think about this before it comes.
 
Is the cable OEM Suzuki or aftermarket?
 
Whereabouts did the cable break? If it's right up near the lever end you might have a sharp edge on the lever channel or lever perch that is cutting into it.

And looking at your picture the cable end isn't wound into the mount far enough - meaning you should move the actuating arm back out one notch and screw the cable end further in.
 
Get an OEM Suzuki cable instead of aftermarket.
 
Inspect your lever where the cable runs through it and make sure there aren't any sharp edges. Also look at the threaded cable adjuster on the perch - they are cut down the middle and often have sharp edges to gnaw at the bare cable.
 
Replace the lever and the cable with new OEM Suzuki pieces. The aftermarket stuff is crap, and the OEM bits are only a few bucks more (sometimes less, even).

It's common for the hole in the lever to wear egg-shaped over the years, which doesn't allow the barrel shaped cable end to rotate. The cable bends back and forth and soon snaps.

Also, lube the cable end and the lever pivot with a bit of waterproof grease when you reinstall.
 
Thanks for the replies. I canceled my order for the aftermarket one and will look for a oem one today. I will also make sure it's screwed all the way in at the bottom this time.
 
The lever can also be worn where it rides on shoulder bolt, so look closely or just replace.
 
bwringer said:
Replace the lever and the cable with new OEM Suzuki pieces. The aftermarket stuff is crap,
and the OEM bits are only a few bucks more (sometimes less, even).
Click to expand...
Clutch cable Item #4, part number 58200-45140, cost is $20.86 (your aftermarket cable is #$18.95)

Clutch lever Item #4, part number 57620-49111, cost is $18.08

Clutch spring Item #16, part number 09440-19027, cost is $2.97 each, you will need SIX of them

Clutch cover gasket Item #4, part number 11482-49100-H17, cost is $11.26

When you get ready to check out, enter the word "BANG" in the promo box, you will get free shipping. :encouragement:

.
 
billie, try to start with the clutch arm another spline outward and adjust from there. (More travel/ leverage)
 
I wouldn't be surprised if a PO has fitted uprated clutch springs, so the advice to fit OEM ones is sound. 99% of the time, uprated springs aren't needed, and even if a bit of extra bite is required, 3 uprated and 3 OEM mixed alternately is usually sufficient.
 
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