Clutch cable end

[chrisr65ls]

I'm removing the left hand switch block to respray it. I've disconnected the clutch at the gearbox but can't work out how to get the end of the cable (with the stopper on it) free of the switch block (on the handle bars). Am I supposed to pull it all the way through or something. There doesn't seem to be a grove for it to slide out of and i'ts too big to go back through the back of it.

[Tony Smith]

I'm removing the left hand switch block to respray it. I've disconnected the clutch at the gearbox but can't work out how to get the end of the cable (with the stopper on it) free of the switch block (on the handle bars). Am I supposed to pull it all the way through or something. There doesn't seem to be a grove for it to slide out of and i'ts too big to go back through the back of it.

You will find that the handlebar end of the cable is contained inside a removable ferrule. First turn the adjuster and its locknut so that the grooves in them face forward, you will then be able to pull the casign back out of the adjuster and then bring the cable itself out along the now exposed groove in the perch. When the end og the cable comes loose the containing ferrule will either stay inside the lever or will fall on the floor - do not let either happen.

if you lose that ferrule you will not be able to make the clutch operate properly and you will have to then wait until the one your order from your supplier of choice arrives.

Why did BMW set the cable up that way. Well it is just possible that with the additional ferrule in place your cable will last a little longer than it otherwise might. Or it could be just because they could.

Don't lose the ferrule.

[Matt Chapter]

if you lose that ferrule you will not be able to make the clutch operate properly and you will have to then wait until the one your order from your supplier of choice arrives.

Alternatively, you could be completely unaware the ferrule (I think BMW calls it a nipple?) exists, and slip the cable end directly into the lever.  This will probably work for a while, until the lever wears through and then has a raw edge that cuts every clutch cable you put on.

Theoretically.

[Tony Smith]

if you lose that ferrule you will not be able to make the clutch operate properly and you will have to then wait until the one your order from your supplier of choice arrives.

Alternatively, you could be completely unaware the ferrule (I think BMW calls it a nipple?) exists, and slip the cable end directly into the lever.  This will probably work for a while, until the lever wears through and then has a raw edge that cuts every clutch cable you put on.

Theoretically.

I like your theory.

Have met more than one BMW rider who did not know that the nipple (you are correct) was needed and could not understand why their bike had a "difficult" clutch action and ate cables.

[chrisr65ls]

Got it. Thanks Tony!

[Tony Smith]

Got it. Thanks Tony!

Chris, you are local to me. If you need a hand, just ask

[marcmax]

I may be dumb but I'm not stupid. After the second clutch cable I figured out what was missing.  

[Tony Smith]

I may be dumb but I'm not stupid. After the second clutch cable I figured out what was missing.  

I think that at some stage we have all done dumb things, I'll tell you one day about the really, really loud tappet rattle that resulted from installing the rocker shafts upside down on my R100. Fortunately new shafts/axles are not too expensive and I had lots of stuffed bearings to play with whislt making up a press to change them.

Or I could talk about what happens if you don't do up the gear box output flange to driveshaft bolts tight enough

Or how much pressure it takes to completely strip the thread from a final drive drain........

And those art just a few of my "clangers" ,

[marcmax]

It's good to know I'm not the only one.  

[Matt Chapter]

I like your theory.
 

The only thing I liked about it was after I had the nipple installed, the cable broke at the last clutch pull to get into my mechanic's driveway to get a replacement cable. Luckily I was able to find the nipple there in the street.