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  #1  
Old 9 Aug 2006
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100 GS: Lifespan of clutchcable
Hi there,

my clutchcable ripped again...

This time it lasted at least 18000 km. The 4 before this lasted between 1000 (!) and 8000 km, while the cable which was mounted when I bought my bike (at 56000 km) lasted at least > 50000 km.

All cables ripped directly at the t-shaped metal thing which enters the lever, but I could not find any specific cause.

I am getting tired of having (expensive) clutch cables shipped in for huge amounts of money (YES, I do carry several spares meanwhile).

Is there anything I can do to enhance the lifespan of the clutchcable?

Or is a lifespan of, say, 8000 km normal and I was just lucky two times?

Regards

Lars
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  #2  
Old 9 Aug 2006
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i went throught about 3 cables in 6 months, untill i started drowning the pivot at the lever with never-seize. Now have at least 15k on current cable.
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Old 9 Aug 2006
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What is never size? An oil like WD 40?
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  #4  
Old 9 Aug 2006
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If they breaking close to the pivot point, almost certainly because the pivot is stcking, and forcing the cable to bend. theis work hardens then fractures the cbale. check by watching it. as you pull lever in, if cable bends at all that is the problem. it should remain straight.

I assembled my cable pivots with moly grease. but just besure they are free.
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  #5  
Old 10 Aug 2006
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I had the same problems with my R65 and i eventually figured out the problem was with lubrication. Keep the cable well lubricated, especially after riding through heavy rain for example as this can wash away some of the lube. most times my cables have snapped have been after rain when the cable action gets a bit stiff. I guess also keep the pivot point greased on the lever end. The last cable i broke was directly after riding through a monsoon rainstorm in India. An old guy helped me fix the broken cable and solder it at the market for 20 cents. it's still holding after 50,000 km.
sean
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Old 12 Aug 2006
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Most modern cables are now lined with a nylon type material so they don't need lubing. There's no point lubing them especially as the lube could deteriorate the liner and then it sticks. My R100GSPD had a very juddery clutch lever action and it turned out to be the plastic clutch release piston which the release lever bears on. It was contaminated with (leaking) gearbox oil which had caused the plastic to swell very slightly causing it to jam in it's housing. It's close tolerance. It's A$90 to replace and the replacement is acting up too. I need something turned up out of teflon or similar.
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Old 17 Aug 2006
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Ok, to recap;
Yes, lube the pivot at the handlebar end of the cable.
No, don't lube the inside of the cable, it only collects dirt.
And yes, carry a cable repair end. It's a barrel with a set screw that can be attached to the broken end of the cable.
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