Clutch cable replacement

[Billmc]

Snapped the clutch cable at the hand lever near the end of a beautiful 6 hour tour through some of the best roads ANYWHERE, in the Texas Hill Country on Sunday. Was shifting a BUNCH (very technical roads)!
Have a new one ordered from Boxer2valve.

Any hints, help or suggestions on the replacement process?

[Tony Smith]

Check that the ferrule is still in your clutch hand lever and if it is - secure it. If it is not, ring your supplier and have one added to your order.

[nhmaf]

+1 what Tony said.  Further, check that the ferrule is smooth on its surface and not all nicked/gouged up, and that there aren't any burrs in the end of the clutch lever where the ferrule rides & pivots.  It the surfaces aren't smooth, they will catch and not allow the ferrule to rotate -> causing the cable to flex right near the end and weaken & break.   Usually a bit of sand paper/emery cloth  can take care of any minor imperfections.   When installing the new one, be sure to smear on some grease on the ferrule to keep it smoothly function and fend off oxidation.

Take pics of the cable routing path through & behind the instrument/headlight area and down along the frame so you properly route the replacement cable.

The instructions in the riders manual for adjusting the cable are basically correct, but can be confusing to first timers.  Let us know if you need help with that.

[Billmc]

Thanks for the tips and the help!
I will try to add to the general knowledge base if I run into any "interesting" developments.

[Rob Valdez 79 R65]

You need to keep that little pocket that the ferrule sits in on the handlebar clutch lever greased!  Also the other end, at the gearbox.  The handlebar is the most critical, though, as you found out.

[jamo]

Order the nylon bush for the handle bar lever as well. My cable broke last month the bush was so worn could not get the adjustment at the lever until replaced there are vids on utube showing replacement and set up.

[Bob_Roller]

For the adjustment of the clutch cable, I don't know if you have ever had a manual transmission car, but the same holds true for BMW motorcycles .

You need a bit of free play at the hand lever, and a bit of free play at the transmission end, before the clutch is activated .

[jamo]

Fit cable adjust cable measuring to the bottom nipple to the cable location 201-203mm using the handlebar adjuster. Then loosen the 13mm lock nut on the clutch centre. Loosen the 10mm centre bolt checking the lever play is 1.5-2mm. Pull in the lever and tighten the 13mm lock nut. Job done. If you replace the nylon bush in the lever you usually have to free off the pivot with a needle file. It is dead easy really[ch128512]

[jp9094]

Also make sure there are no sharp bends when routing the new cable. Mine broke because the handlebars were not the stock flat "clip on" style and the cable made an acute bent to go under the instruments. Check out the thread I started about this in June.

FWIW

[Billmc]

Thanks for all the input and help. Finally got around to doing the job last night and was successful.

Here is what I encountered:
1. The ends of the new cable are aluminum instead of steel.
2. The new cable is thicker by a couple of strands than the previous one (not sure it was original).
3. The new cable end at the hand lever needs "modifying" with a fine file and emery paper in order to fit in the ferrule of the lever.
4. A light coat of grease on the ends works wonders!
5. On this Monoshock R65 I had to remove both mufflers and the 'front muffler' in order to reach the adjusting nut and screw at the transmission arm. (didn't expect that!)
6. It only took about 20 minutes to remove, replace, adjust and check the clutch cable (not counting the muffler removal and reinstall)
7. Learned more about the engineering of the motorcycle.(amazing machines, but you already knew that)
8. The adjusting nuts at the handle are brass! (they were painted. Not any more, they shine!!)
9. The rubber boot at the handle does not come with the cable, even though it shows as included in the add)
10. Shiner beer tastes really good at 11pm after finishing a job!