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Author Topic: 3rd clutch cable break in 5 000 km?  (Read 247 times)

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Offline Archangel

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3rd clutch cable break in 5 000 km?
« on: December 08, 2017, 02:54:57 pm »
Am I doing something wrong?

Got the bike with 15 000 km on the clock and I've gone through 3 clutch cables from then to the 20k mark. They all break off on the nipple at the lever.

Any ideas? Should I get stronger gauge cables made up?

Online I&horse

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Re: 3rd clutch cable break in 5 000 km?
« Reply #1 on: December 08, 2017, 03:03:54 pm »
Do you grease the nipple/ball?

There may be something "grabbing" the nipple/ball bending the cable instead of the ball turning inside the socket.
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Offline Archangel

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Re: 3rd clutch cable break in 5 000 km?
« Reply #2 on: December 08, 2017, 07:37:11 pm »
After removal of the cable and thorough inspection, there seems to be more than the usual up and down play, perpendicular to the cable travel direction. I think there may have been a washer or spacer that is missing or deteriorated and fell out. Further to that, the edges on the inside of the casing was pretty sharp, so I sanded them down a bit.

Let's hope that it lasts this time...  :thumleft:

Offline TK

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Re: 3rd clutch cable break in 5 000 km?
« Reply #3 on: December 08, 2017, 07:59:45 pm »
I had a couple of cables made up purely due to the same problem that you have.......breaking at the nipple. But by mistake/miss-communication  had ordered them with smaller nipples. Haven't had a problem now in at least 12000km.
 

Offline BiG DoM

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Re: 3rd clutch cable break in 5 000 km?
« Reply #4 on: December 08, 2017, 08:20:04 pm »
The problem is that the cable end ferrule is too small for the lever adjuster. This means that it pulls at an angle resulting not only in a harder pull but also friction and failure at that point at the lever. The fix is one of two things - have a cable made up by Cableman (or other cable maker - they can copy an original and use the cover if necessary and also make a slightly stronger cable) with a larger OD ferrule that matches the lever adjuster. OR make a collar ferrule adapter as pictured below to take up the slop in the adjuster with the result that the cable will exit the lever at 180 degrees. It has a slit so it can be slipped over cable. My initial fix was to wrap a thin strip of Coke can around the ferrule.
« Last Edit: December 08, 2017, 08:22:30 pm by BiG DoM »
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