Bonkorama Posted October 28, 2007 Posted October 28, 2007 98 R1100RT, 105k miles. Replaced a broken clutch cable today, I wasnt stranded (I have a redundant clutch cable threaded already side-by-side to prevent road-side yelling and tantrums) but this is the second cable in a little over 12 months. Cable frayed and popped at the bead near the lever (they have all done that). Anyone else going thru a cable at 1 per year? Nothing seems abnormal about the lever, friction nor the path of the cable to the clutch pull near the tranny. hmmmmm.
ShovelStrokeEd Posted October 28, 2007 Posted October 28, 2007 You really need to lubricate the hole in the lever where the ferrule engages and you should do this at every service. As soon as that starts binding it will quickly kill the cable. I used to dismantle and lube with anti-seize but I have also used some spray in stuff. Either chain lube or dry moly in a spray can. Both are messy though and I think taking it apart and smearing is the better way.
ahirsch Posted October 28, 2007 Posted October 28, 2007 Are the two cables wearing against each other? Is their sufficient room for two to run side by side? Just a thought.
Bonkorama Posted October 28, 2007 Author Posted October 28, 2007 ooooh, i realy like the chain lube idea. i bet that would stay put. And no, there isnt anty probelm with the cables rubbing or binding, its pretty much a straight thru from the lever to clutch. Could it be all the LA City traffic I drive? Maybe it seems like a short TIME between replacements but in reality is normal in terms of pull-release quantity being high from all the stop and go? Something to think about. in the meantime.... i think im gonna get me some chain lube.
smiller Posted October 28, 2007 Posted October 28, 2007 Cable frayed and popped at the bead near the lever (they have all done that).You have me wondering if there is anything I should be looking for but I'm still on the original cable on my RT (at 10 years/90k miles) and I just inspected the area you described and can't find the slightest sign of fraying or wear of any kind... it could just as well be new from just looking at it...
OoPEZoO Posted October 28, 2007 Posted October 28, 2007 Check for burrs where the cable connects to the lever. a little rough spot would kill a cable pretty quickly. I had a cable fail on me last month........its not a good feeling when you get it pulled in half way and feel that *TWANG* of the cable starting to let go. I managed to milk mine back home, and found that only 2 of the maybe 12 strands were holding. It was on the bike when I bought it so I don't know the mileage, but it was enough for me to buy a spare to have sitting around and to take on trips with me.
Bonkorama Posted October 29, 2007 Author Posted October 29, 2007 but I'm still on the original cable on my RT (at 10 years/90k miles) I am simply spellbound by this. Speechless. wow. ok, I recovered.... what type of riding do you do mostly? Long Distance? Commuter? Weekends Only? I wonder if my problem is just all this LA City million-clutch-pulls a year thing.... Keith - I * will * check for burrs tho. I think thats a great suggestion, and probably likely. Ill let you know how that goes.
upflying Posted October 29, 2007 Posted October 29, 2007 The cable barrel in the lever needs frequent lube. It needs to roll a bit each time the lever is moved. If it binds the cable will quickly wear out. I have the same clutch cable my bike had when I bought it at 36k miles. I now have 63k miles and do a lot of stop and go riding.
Stan Walker Posted October 29, 2007 Posted October 29, 2007 I think you have a problem. The barrel isn't rotating which causes the inner wire of the cable to flex and break. A bind, lack of lub, etc. I replaced the cable on our '96 R1100RT for the first time at 70,000 miles. Cable ends were fine, no signs of broken wires, but it was getting harder to pull. Probably wore through the inner sheath somewhere in the middle of the cable. I clean and lube my barrels (both ends) every 6000 mile service. Stan
smiller Posted October 29, 2007 Posted October 29, 2007 ok, I recovered.... what type of riding do you do mostly? Long Distance? Commuter? Weekends Only? All of the above, including being a daily commuter both here and for many years in California. No fraying and the cable pull is smooth, and like Stan when it does go I expect it will be due to wear in the sheath rather than wear of the cable itself. If your cables are wearing that fast then I agree that there is likely something wrong with your installation, although I don't know what. It may be lubrication of the ferrule end of the cable but then again mine has received only the most casual and infrequent lubrication over the years and still no problems.
DavidEBSmith Posted October 29, 2007 Posted October 29, 2007 And it should be noted before anybody gets any bad ideas - it's a good thing to lubricate the ferrule on the end of the cable where it fits into the lever. It's not a good thing to lubricate the cable itself. The cable is lined and lubricating it with a wet lubricant can make the lining swell and bind the cable.
AndyS Posted October 29, 2007 Posted October 29, 2007 but I'm still on the original cable on my RT (at 10 years/90k miles) I am simply spellbound by this. Speechless. You shouldn't be spellbound by this. The amount of force required to actuate the clutch is tiny in comparison with the tensile strength of the cable and the method of attachment to the nipple. What you should be concerned with is why YOURS failed. As suggested you may have a burr where the cable articulated within the lever housing, or maybe an accident has distorted the lever. Maybe an aftermarket cheap cable. BUT for sure there Must be a problem there. As for using chain lube - not a bad idea, but the thought of chain lube on a BMW really goes against the grain All the best Andy
Bonkorama Posted October 30, 2007 Author Posted October 30, 2007 Gonna check my lever today for weirdness. I bet when I attempt to put chain lube on my bike, its gonna react like my cat when I tried to put eye-drops on her.
RFW Posted October 30, 2007 Posted October 30, 2007 I had exactly that problem with my K100. I got tired of paying $40 every year for a new cable that is supposed to "last the life of the bike", so I did a little detective work and found the cause... The problem was that the cylindrical "swivel" that terminates the cable at the lever end, was slipping down (out of its socket in the lever) very slightly, and so the cable was no longer properly aligned in the lever. So, when you pulled in the lever, the cable snagged on the slot in the lever (the slot through which the cable passes out of the lever into the lever mount), causing the cable to bend slightly, right at the point where it comes out of the swivel, every time the lever was pulled in. Eventually the cable fatigued and broke. The solution was that I drilled and tapped a small M3 hole un the lever, on its underside, right next to the hole where the swivel fits. Once the cable was installed, I screwed in an M3 screw with a washer under the head. The washer overhangs the edge of the swivel hole, and prevents the swivel from dropping down (slightly) out of its socket, and that keeps the cable from snagging on the slot in the lever.
ShovelStrokeEd Posted October 30, 2007 Posted October 30, 2007 Good tip, Bob. I have had this happen on other bikes and solved it in various ways, mostly by using a die grinder and removing the lower portion of the cable guide slot in the lever. Putting in a stop, as you have done, is a bit more elegant a solution.
Bonkorama Posted October 31, 2007 Author Posted October 31, 2007 I think you are right. I was looking at it again this morning as I was leaving, and I seem to remember that ferrule sitting low in the hole. Im going to look at how it plays against the rest of the lever tonight with a good light and a magnifier. Excellent detective work. I cant imagine what else it could be.... Ill post my results later tonight of my own Sherlocking.
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