Clutch Cable

[Crossrodes]

Last year my clutch cable failed.  It came apart at the clutch handle.  This year the same thing has happened.  I've probably got about 5,000 kms on this cable.  Is this normal for these cables to fail like this.  I bought this cable from BMW. :-/

[montmil]

Should not fail that soon!

Suggest a very close inspection of the clutch lever recess where the cable's barrel end fits- look for a burr or spur that might be a concern. Also, the barrel should have some lubricant to permit rotation. I use a white grease. Look over the perch, too. Same deal... boogered up metal interfering with the cable's smooth operation.

Let us know if you find something. Good hunting.

[nhmaf]

+1 with what Monte said - the barrel end is supposed to ROTATE smoothly in the lever end, and the cable strands should not appear to bend.   If they do, the cable will break in short order.    Keeping that round recess of the lever smooth and greased (I use a dab of the sticky red grease myself) is important to long cable life.   If the lever end is severely chewed up or has been worn into an oval shape, then you should replace the lever as it will just continue to repeatedly bind up the barrel and wear the cable out.   If the lever recess has minor scratches/nicks you can usually restore it with some find  sandpaper and small wooden dowel

[Crossrodes]

Thanks guys.  I can't check it out now (currently working on an old truck) but I'll check those items when I can.

[Julio A.]

I'd also like to add the possibility of a worn out plastic bushing between the lever and the screw securing the lever. It wears in an oval shape and makes the level pull the cable in awkward angles.

[tvrla]

+1 on Julio's suggestion. If the lever feels pretty loose in the perch, yet the pivot screw is tight, check the plastic bushing in the lever.

[Crossrodes]

Guys thank you all for your inputs.  

Today I removed the old cable and checked all the parts against the parts list in RealOem.  It turns out that I am missing a bushing that fits in the handle where the cable attaches to the handle.  I have a new cable (always carry it with me just in case) so I have ordered one more cable plus the bushing.  It looks like I won't be getting it for a couple of weeks as it has to come from Germany.

[Matt Chapter]

It turns out that I am missing a bushing that fits in the handle where the cable attaches to the handle.  

Now you're to the critical part.  Here's what happened to me:

My clutch cable broke the first time, I lost the bushing.  New cable, everybody's happy.
Until, it "broke" the second time.  No bushing, the cable end pulled through the section of the handle.  Started to replace the cable, realized I needed the bushing, replaced that.
And then, since the handle was sharp, it broke again even after the bushing was supplied.
Final solution: new cable, same bushing, new handle.

The morale of the story is: make very certain the handle is not sharp or burred.  I use my old handle for a paperweight at work now.

[tvrla]

The littlest details can turn mole hills into mountains, huh?

[Matt Chapter]

The littlest details can turn mole hills into mountains, huh?

Did I mention that the second time it happened, it was in rush hour, up hill, on a 4 lane divided highway with traffic signals?  In the May Texas heat?  Made it interesting to go clutchless home.

Ugh.