clutch cable problems?

[butticci]

My clutch cable is breaking about once a month I think the bead on the lever end of the cable doesn't seem to be pivoting inside the lever. Has Anyone had this problem? Any suggestions on fixing this problem?

[Coady]

Most likely the cable is rubbing on the threaded part of the adjuster that goes into the clutch lever. Try winding it out further (and adjusting cable at other end to compensate), make sure its lubed up at theat point and my adjuster has a gap running along one part of it - If I line the adjuster up such that the cable runs in that gap it reduces the amount of surfaces to rub on.

Also the suzuki OEM cables seem more robust than than the cheaper motion pro.

[bwringer]

I'd also add that a new OEM lever may help -- the cable hole where the "bead" pivots often wears out quickly on aftermarket levers.

You are installing the cable with a smidgen of grease around the "bead", right?

[yasser]

I just put a cable on my bike with that came with a nylon sleeve on the button. The sleeve is slotted where the cable enters the button. I think the idea is to a allow the sleeve to slide or take the brunt of the wear. Maybe they all come like that but my last one didn't and I thought it was a nice idea. we'll see I guess.

[Suzuki mad]

Are you using an aftermarket or genuine Suzuki cable?

[argonsagas]

Breaking cables can happen, but if you have to replace them because they break frequently you have one (or more) of three problems.

(Lubrication or internal wear would be obvious considerations, but both seem quite unlikely if you are replacing entire cables frequently.)

1-cable is improperly mounted, either at the lever perch or at the engine end.

This could be due to worn or bent perch or lever on the handlebars, or a bent or improperly aligned mount at the engine end.

2-at the engine end, the release arm the runs into the case is binding or bent.

3-cable routing. If the cable bends sharply at any point the internal constriction causes the inner cable/wire to bind inside the sheath and friction increases greatly. This is a common reason for failure.

[headsbikesmopars]

I think the problem is where the cable is breaking. See if you can see what the problem or binding is right in the area where it breaks. Does it break in the same place each time or does it break in different places ? If in the same place there has to be evidence at that spot. Is something 'filing' it ..cutting it ? Let us know what you find.

Terry

[dlanes]

Yah, I my clutch cable just snapped tonight after being replaced just a month ago. My friend who I was riding with today also snapped at the same intersection (weird huh?). He just replaced his a week ago. Is there something I should know about installing a new one? I am not sure if my clutch lever is oem or aftermarket, but that's where it snapped before. Should I be looking for another lever? Also read you need a little grease?

[tkent02]

Put on the correct Suzuki cable, grease the bearing in the end of the cable that goes into the lever, and get your eyeballs in there and watch how it works. If the cable is scraping on anything, or if the inner cable itself is bending at all as the lever moves, you have something wrong. Could be bogus levers, mismatched perch, something in there may be bent, we can't see it from here unless you post pictures. Possibly the hole in the lever where the cable end bearing goes has been worn into a funny shape? Maybe the slot has been pinched shut?
Look at your broken cable, can you see if it has been partially cut, or has it been bent too many times? Did one or two strands break at a time or all at once? There are clues, you need to find them.

Oversized clutch springs tend to wear cables out faster than stock ones but not in just a month.

Cables should last for many, many years.

[dlanes]

Put on the correct Suzuki cable, grease the bearing in the end of the cable that goes into the lever, and get your eyeballs in there and watch how it works. If the cable is scraping on anything, or if the inner cable itself is bending at all as the lever moves, you have something wrong. Could be bogus levers, mismatched perch, something in there may be bent, we can't see it from here unless you post pictures. Possibly the hole in the lever where the cable end bearing goes has been worn into a funny shape? Maybe the slot has been pinched shut?
Look at your broken cable, can you see if it has been partially cut, or has it been bent too many times? Did one or two strands break at a time or all at once? There are clues, you need to find them.

Oversized clutch springs tend to wear cables out faster than stock ones but not in just a month.

Cables should last for many, many years.

Yah, the cable was replaced by one straight from suzuki. Just noticed tonight that it was starting to fray and it snapped shortly after I noticed. I think it may be the lever. I'll look into it more tomorrow.

[dlanes]

I thought I would post and update to help someone in the future. It turned out there was quite a bit of play in the clutch lever, I'm guessing thats what caused the problem.