clutch cable breaking

[crazy_dan]

Hey there howdy everyone...

i've got an 81 r65 and i've just broken my 2nd clutch cable in less than a year.  they keep breaking at the end where the ball goes into the barrel then into to lever.  any suggestions what to look for, or was the first one just an old cable and the new one was defective?

[Bob_Roller]

My original clutch cable broke at around 14,000 miles, at the same place as yours.

Your first cable failure could have been from use, but the second one failing so quick, would make me believe that when the cable end was swaged on, it was swaged to tightly, and started to break the strands of the cable.

How much effort does it take to move the clutch lever when the cable was installed ?

There a two bearings at the transmission where the arm that the cable attaches to.

They may need some cleaning and re-lubing.

[Justin B.]

A cable breaking at this point usually indicates the pivot pin/barrel needs to be cleaned and lubed.  This pin is supposed to rotate in the lever and when it gets gummed up and doesn't the cable is then required to flex every time you pull in the clutch.  You all know what happens to wire when you bend it back and forth too many times...  This should be part of the yearly maintenance.  Attached is a maintenance checklist I use:

[Lowen]

Went through three clutch cables the first summer I had my R65 till I found out you had to smear grease from the lever to the cable housing, had a similer problem with not lubing the splines on my throttle gear.

[nhmaf]

I would add to Justin's comments that you might have a burr or non-smooth surface inside the "cage" end of the clutch lever where the clutch cable
pivot goes in.  Before you re-grease, I would carefully clean it up and use an emery cloth or gently use a round file if you detect and sharp edge, nicks,
or burrs that could be causing the cable to not pivot,  Put on some grease that will stick in place pretty well, and work the clutch slowly while watching it closely
for smooth rotation in that joint.  If the lever end is too badly gouged up, it might makes sense to get a new lever while you are at it.

[Rob Valdez 79 R65]

click for larger image

[crazy_dan]

it was gummed up just a little bit where the barrel goes in to the lever, cleaned it up and pulls beautifully.

thanx for the advice!