broken clutch cable - Wrist Twisters
 
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post #1 of 20 Old 07-04-2014, 08:03 AM Thread Starter
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broken clutch cable

So I've been having some issues with my clutch cable lately. First I adjusted it then the nuts at the clutch arm kept vibrating loose and backing off. So I loctited them in place the 2nd time it did it. Is that normal? Or did I just not have them right enough to begin with?

Then last week on my way back from a camping trip, taking some mtn back roads.. I felt it get loose and..snap.. Went clutchless till I had to stop then bumped it. Tried after the 2nd stop but

I wanted to see why it snapped tho because it looked pretty cleanly sheared off. it looks like the clutch lever could be responsible. There is a bit of a groove worn in the Al from the cable and when you squeeze it you can see where it pulls on the cable. See pic. Should I file this down or something? I think they are crg levers.
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post #2 of 20 Old 07-04-2014, 09:54 AM
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If that lever is installed corectly, that's a terrible design. You can clearly see where it's bending the cable over an edge and, yes, that's going to wear/break your cable. If it were me, I'd get a OE lever.

Robert

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post #3 of 20 Old 07-04-2014, 10:36 AM
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No way that's installed right.

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post #4 of 20 Old 07-04-2014, 10:42 AM Thread Starter
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Yea there's enough people with aftermarket levers they should work.

Any tips on what might be installed wrong?
They are adjustable levers. That was on the mid setting.
These came with the bike and I'm not sure what model they are designed for. But other than this they fit and work great. By the build quality I'd say they are one of the higher end options. Wonder if I could stick a router bit in there and clear a channel for them to go in

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post #5 of 20 Old 07-04-2014, 11:46 AM
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My guess is that the lever you have was not designed with the 919 in mind. The braided cable should not touch or bend around anything. The contact and pivoting movement should only be at the cable end.

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post #6 of 20 Old 07-04-2014, 11:49 AM
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I agree, it doesn't look like the right part.

...on my droid.

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post #7 of 20 Old 07-04-2014, 12:47 PM Thread Starter
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Soooo...anyone wanna buy some levers

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post #8 of 20 Old 07-04-2014, 01:55 PM
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Only if they come with the curse of a 1000 gypsies...

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post #9 of 20 Old 07-04-2014, 02:48 PM Thread Starter
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999... But... I'll throw in a Corbin some forks

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post #10 of 20 Old 07-06-2014, 08:14 AM Thread Starter
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can someone snap a pic of their levers by the cable? i'm thinking about cutting a section out of the lever so it doesn't rub at that spot anymore.. or maybe just rounding that edge with a file.

I got a new oem cable and but i also took the cable off my friends 600rr, it's about the same length just without the plastic elbow at one end.

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post #11 of 20 Old 07-06-2014, 09:38 AM
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Just play around with it, sure you can't make it fit like it's supposed to?

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post #12 of 20 Old 07-06-2014, 09:52 AM
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Quote:
Originally Posted by Ditch View Post
Just play around with it, sure you can't make it fit like it's supposed to?
TWSS

Here's a quick pic of the OEM with the cable in the slot.
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post #13 of 20 Old 07-06-2014, 09:53 AM
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Walked right into that one...

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post #14 of 20 Old 07-07-2014, 09:45 AM
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These are fairly new CRG levers.


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post #15 of 20 Old 07-07-2014, 09:48 AM
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Disclaimer: The above photo was produced by Micheal Bay.
Sorry about the lens flare.

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post #16 of 20 Old 07-07-2014, 09:54 AM
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Quote:
Originally Posted by Ditch View Post
Walked right into that one...

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post #17 of 20 Old 08-27-2014, 02:35 PM
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quick snapped clutch cable question...
background...it's time to replace it...the most recent adjustment and lube was clear that there wouldn't be another adjustment...it's pretty stretched...it started shifting a little hard and I noticed there was a LOT of slack at the lever end of the cable...tightened it up some (then it was too tight..so backed it out just a bit)...still after tweaking it...shifting was rough...I immediately thought worst case...and started sopping for a clutch...I have a 50 mile commute home...2 miles from the house...it snapped at the lever...I haven't dug into it since last night but am about to when I get home tonight...in the collective years of experience here...is my first theory of clutch cable the likely culprit of the whole issue??...it's going to be the first step anyway...but...100 miles a day on my 919 is far more economical than my 4 wheeled money pit

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post #18 of 20 Old 08-28-2014, 06:27 AM Thread Starter
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I'd start with the cable for sure.
due for an oil change?

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post #19 of 20 Old 08-29-2014, 02:32 PM
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nah...it was just done a couple months ago...well...not long ago...but it wouldn't hurt for sure to do another...while I'm doing stuff...and throwing money at it anyway...

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post #20 of 20 Old 09-01-2014, 05:50 PM
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I just replaced my clutch cable today and it was one of the best things for the money I have done to the bike. It took me a lot longer than it should have but it still wasn't too bad. The best thing I did was to attach the new cable to the old before pulling it out. I also found it easier to feed back up through the bike rather than down, but I'm sure that's just preference. On my bike, it just seemed to move easier that way.

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