Clutch Cable Breaking

[leslo]

I've broken 2 new clutch cables in 4 months. No matter how I position them they make a snapping and crackling noise when I pull it. The cable is braking at the lever.
I bought the bike 5 years ago and never had a problem with the cable. It looked really old and not knowing the age of it I decided to replace it. Both I've bought from Dennis Kirk and both have snapped.
Any ideas?

[Joe Nardy]

I've heard the quality of some aftermarket cables is nowhere near the quality of OEM cables. You might see if they are still available from the dealer. Also check the lever and cable adjuster to make sure they don't have any rough edges. Make sure the cable routing doesn't cause any tight turns. The lever may have a plastic or bronze (brass?) bushing that encircles the cable end. If the bushing is worn or rusted it might accelerate cable wear. I was able to get a new lever and cable from a Suzuki dealer last year. I lube the exposed sections of cables with grease, then make a tiny paper funnel, hang the cable from the garage door rails, and fill the funnel with 30w oil until it runs out the other end. I've tried the cable lube kits and they're just a mess. The paper funnel method works better but takes longer.

Thanks,
Joe

[bwringer]

I've seen problems like this caused by bad clutch levers. The hole where the cable end rides wears out and gets oval shaped. When you pull the lever, it traps the barrel-shaped cable end so it can't rotate, and thus bends the wires sharply and causes the cable to snap pretty quickly.

Aftermarket levers are pretty bad about this. You can get OEM levers for not much more money, and they're worth it.

If the cable is breaking somewhere else, then, um, never mind...

[flyingace]

What Brian sez makes sense - as if the cable end is binding and bending the cable every time you clutch. You should be able to visualize if that's happening. Maybe a nice glob of grease on the cable end would make a difference?

[chuckycheese]

Right

I think bwringer has "hit the nail on the head"!!

[focus frenzy]

if they are motion pro cables, THAT is your problem, they are about the size of a bicycle cable and the ends pull right off.
my factory original (with adjustment in the middle!!) 25 year old clutch cable finally gave up the ghost this spring and I got a motion pro cable and it lasted one month!

I now have a OEM Suzuki cable on it and it is doing good, it is not as thick as the original but it is much thicker than the motion pro cable.

also the Suzuki cable comes pre-lubed with some seriously slick lube!