Another clutch cable snapped in a months

Comfy Old Boots

Comfy Old Boots

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I'm not having much luck with clutch cables. Another one frayed and snapped at the lever.

I'm just wondering if I'm missing a part at the lever end causing it to fray. To my eye it looks like the cable is rubbing against bare metal where it feeds through the hole and then on into the nipple holder on the lever itself.

Should there be a plastic sheath or equivalent in the hole the cable fits through in the lever mount? Excuse the description but hopefully you know what I mean.

Thanks.

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how about the other end?

Hi I am sure someone more qualified than me will be along in a minute, with an answer, but I had a similar problem which was resolved by cleaning and lubing the clutch arm pivot at the gearbox end. From your description, there doesn't sound as if there is anything missing from the lever end. You don't say if the clutch lever has a heavy action or not, but it might be worth checking, the pivot arm. There is a bush in there that can wear and "seize" up.
Good luck and I hope you find a solution soon.
 
Smelly Old Boots said:
To my eye it looks like the cable is rubbing against bare metal where it feeds through the hole and then on into the nipple holder on the lever itself.
Click to expand...

Seems like the part of the lever where the cable comes out, is worn, or has a sharp edge.
The barrel on the nipple of the cable should rotate in the lever when pulling that lever, not the cable bending.

You can rework that area with a small file and see if things improve, or get a new lever.

Or, as I did on my bike, drill and tap a small hole in the lever and fit a strip of sheet metal to keep the barrel up inside the lever.

Paul.
 
As mentioned above, the barrel in the lever should be able to swivel around. They get worn oval and are no longer able to swivel when the clutch lever gets pulled, which puts a kink in the cable near the nipple which then breaks.

The lever will also get worn along with the nipple barrel. best replace both. And then grease them every service. One of those things usually overlooked by owners, who seem to think just an engine oil and filter change is a service.
 
Thanks folks. Appreciated.

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Cable

I guarantee this is as Steppers says my mate had just the same problem, best thing change the whole pivot assembly but you'll have to remove the rear frame first.
 
Btw, yes I've had a heavy clutch for a while... I might take a look. Thanks lads. Gives me loads of info.

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I'm going to try and retap the part in the top picture _ well my mate will. I'll buy a new lever you can see the wear and tear. Nipple bracket moving freely in the lever BTW. Anyway back on the road for the moment.
 
Well , I didn't bother and just gutted another cable. Mitorworks have delivered new parts including a new felt ring. I might be back tomorrow when I try and fit them to the cast bars.

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uploadfromtaptalk1400943175527.jpg leaving aside the fact my levers are silver, will this got an r850r with cast bars?
 
Where does the felt piece go? Over the end of the lever part of the cable?

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And to end it all , exactly what does the switch that's housed in the lever do? Bike seems to run perfectly despite it getting sacrifised During the transplant!

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Not familiar with the levers on your bike but switch with the clutch will all be part of those wonderful safety features, connected to side stand switch to stop you riding of with the stand down or trying to start the bike in gear (somebody here my correct me though)

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It allows you to re-start the bike while it's in gear when you pull the clutch in. Saves you having to pratt about finding neutral if you stall it at lights etc.

Won't work with the side stand down.


And while you're messing with the clutch cable, I really would recommend you take the time to have a look at the actuator arm at the back of the gearbox.

Yes, I know it's a pain to get to, which ever way you go (Swing arm off or not. If you go the 'not' way, make sure you have a magnetic pick-up tool to hand), but not as much of a pain as it is if it snaps.

They do snap, and they aint cheap. I speak from experience...:rob :blast
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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