My riding partner picked up a 96 R1100RT. I bought one a couple of months ago. same year fewer miles on it. Today his clutch cable broke. The PO said they had recentoy changed the clutch cable. We ordered a new one. Is there some trick or something when we install the new cable so It lasts longer than the one that just broke. He also said the clutch was slipping before the cable broke but after It broke the clutch never slipped again. We both have airheads. are the clutch cables similar? thanks for your time.
Two things. First, lubricate the barrel of the cable at the lever end. Make sure the barrel rotates as you squeeze the lever.
Second, there are two measurements you need to know, and two spots to adjust the cable. First, you need 12 mm of space between the lever housing and the adjusting wheel. Second, you need 7 mm of freeplay at the lever itself. With a new cable you should set the 12 mm number, then use the adjuster at the back of the tranny to set the 7 mm number.
From your description it sounds like there was not enough freeplay in the lever. The 7 mm number is the important one. Once you have everything set to spec, the 7 mm will change over time. Use the adjusting wheel on the lever to reset the 7 mm. That will change your 12 mm number. Eventually you will have to reset the 12 mm number again.
The link below has a clutch adjustment description:
+1 on that! Also, there is a small inexpensive plastic bushing in the pivot of the hand lever (mine was almost worn through). Easy to replace. But the proper lube of the lever pivot and cable end barrel are essential to insure there is no flexing of the cable at the hand lever end. I'm assuming that is where it broke?
The original cable on my 94RS was still working at 115,000 miles, but I replaced it because the outer casing started to crack. I must have missed up proper lubing, regularly/yearly, because the replacement cable snapped off at 40,000 miles. New one is in, adjusted, lubed and working great. Very easy to replace too.
If these are Teflon-lined cables. . .and I think they are, don't use cable lube in the sheath.
+1 on the lever-end lube of the barrel -- I bet 90% of them break here.