Clutch cable blues

[rtbuzz]

Riding through downtown Boulder today my clutch cable snapped right down to one strand od wire. I was able to nurse it home using rpms and the throttle to shift. I had the cable replaced 8 months ago (about 4,000 miles worth). It broke between the hand lever and the cable housing. Is this a common problem for a 1983 R80RT ?

[manicmechanic]

I had that happen on an '84 R100RT. Make sure that you lube the cable end where it goes into the lever, and make sure also that the cable end barrel rotates in the lever recess. Otherwise you'll just bend the cable there and cause it to break.

[dbrick]

When a clutch cable breaks like this, it's almost always because of insufficient lubrication at the barrel end.

The end of the clutch cable is a little nipple, which seats into a little barrel, perhaps 1/4" long and 3/16" in diameter. The barrel slides into a recess in the hand lever. When the clutch lever is squeezed, the angle between the barrel and the clutch cable changes; the barrel is supposed to rotate within its recess so that the clutch cable is always pulled straight out of the cable sheath. (This isn't particular to Airheads; the same issue arises in Ks and Oilheads, except those with hydraulic clutches.)

When the barrel can't rotate - because it's not lubricated - the clutch cable bends sharply at the nipple, and, as you found, eventually breaks. To lube, slacken the clutch adjustment, and disconnect the cable from the hand lever by pushing the barrel out. Clean all the parts. Lube the recess with a moly grease, and reassemble. When you squeeze the hand lever, you should be able to see the end of the barrel turn. Properly lubed (and kept lubed, it *is* out there in the weather, after all) the clutch cable will last almost forever.

[John Brase]

I replaced my clutch cable a couple of years ago, not because it was bad, just because it was 25 years old. But, I left the old cable in place - held on to the frame with cable ties. This way, if the new cable breaks there is a spare at the ready just waiting to have the two ends connected. Riding without a clutch is no fun. Especially at stoplights. :doh

John

[riderR1150GSAdv]

I replaced my clutch cable a couple of years ago, not because it was bad, just because it was 25 years old. But, I left the old cable in place - held on to the frame with cable ties. This way, if the new cable breaks there is a spare at the ready just waiting to have the two ends connected. Riding without a clutch is no fun. Especially at stoplights. :doh

John

That is a great tip!! :thumb specially if a lot of tupperware needs to be removed to get at the cable(s)

[Cal]

Replace your clutch lever when you mount your new cable and ferrule.

Cal Garcia
Sarasota, FL