clutch cable pulling through clutch lever on '83

[tc80211]

Hey Guys,

It's been while. Put about 2K on my R65 since finishing it and could not be happier. What an amazing machine!! And so care free until my clutch cable pulled through my clutch lever. Very odd.

Upon closer inspection of the lever it looks like the cable end actually wore away the inside of the lever until it has nothing left to bite onto. I pulled it in while on the highway and it came all the way through! Luckily got home safe.

Any of you experience this before? Should I just repace with another BMW original lever (this was just that, I had to replace when restoring the bike... it was off another '83 R65) or should I do something else? Maybe a newer lever?

Any suggestions as always would be great!!

[marcmax]

I had a similar thing happen when I first got my '82. The previous owner had installed a replacement clutch cable and didn't replace the nipple holder (part 7) in the drawing, BMW part 32721233550.

The nipple on the end of the cable is barely large enough to stay in place and will either pull through or the cable will wear through and it will come off. This part fits over the cable and then into the clutch lever.

[montmil]

A small dab of Lubriplate white lithium grease will help keep that new #7 cable barrel working smoothly inside the lever. Your local BMW dealer should have this simple part.

[mrclubike]

If you look at the lever from the bottom you will see the round hole #7 fits into

[Tony Smith]

Fell for this one myself once.

If you cannot find one at your BMW dealer, find somewhere or someone who works on old English bikes. The nipple holder is a standard Bowden part.

The nipple holder is usually lost when the cable breaks and the nipple holder, relieved of tension vibrates free and escapes. A way to prevent this, or at least slow down the process is to use heavy axle grease as the nipple holder lubricant, if/when the cable breaks, the heavy grease will retain the nipple holder.

As Montmil knows, under the tank master cylinder /6 & /7 have two of the little blighters, although I am here to tell you that when your brake cable breaks, the whereabouts of the nipple holder is surprisingly low on your list of personal priorities.

[tc80211]

holy shit. such a simple part. no clue how i overlooked it!!
As always, thanks a million guys!
Ordering it now!

[marcmax]

You have a good source of parts nearby 441 Cycle Shop. http://www.bmwmotorcyclesftlauderdale.com/

[Matt Chapter]

This happened to me, and it caused trouble quite a few times until I got it all nailed down.  Here's how my chain of events went:

Buy the bike, ride it a few 000s of miles, cable breaks.  Replace the cable, fine for a few more 000s.  Cable pulls through the lever as yours did.  Take it into the shop, they give me the nipple, replace and refit cable, good to go... for another few 000s of miles.  The lever cut the cable where the cable end pulled through, and it broke in the driveway of my local airhead mechanic..  good thing I was there to get a new cable.

I then acquired a used lever and replaced the "worn" lever.  It's now a paperweight on my desk.

Long story short: inspect the lever for damage and replace if necessary.  I tried to file the lever back and was not successful.