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TECHNICAL MOTOBRICK WRENCHING In Remembrance of Inge K. => The Motobrick Workshop => Topic started by: evanwellsk75 on March 08, 2020, 07:07:45 PM

Title: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 08, 2020, 07:07:45 PM
Hey my clutch cable snapped in the middle of marin county in point reyes. This tiny town on a sunday doesnt have a garage open for another 2 days. Its such a simple thing to cause a conundrum but here we are, is there anyone around that can bring me one. Or does anyone have any ideas?

Thanks
Title: Re: Broken clutch cable in the middle of no where
Post by: daveson on March 08, 2020, 07:40:12 PM
In first gear,  push the bike and start it. Time to practice clutchless changes,  like truckies do all over the place.
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 08, 2020, 07:45:55 PM
Quote from: evanwellsk75 on March 08, 2020, 07:07:45 PM
Hey my clutch cable snapped in the middle of marin county in point reyes. . . . does anyone have any ideas?
Here's a time-tested solution (http://www.motobrick.com/index.php?topic=10315.0).
Title: Re: Broken clutch cable in the middle of no where
Post by: daveson on March 08, 2020, 07:59:57 PM
Yep, that's way safer.
Title: Re: Broken clutch cable in the middle of no where
Post by: herseyb on March 08, 2020, 08:32:53 PM
that johnny motobrick ace fix saved my ass one day.  Rode it for like a month after I got the replacement cause it just worked...
Title: Re: Broken clutch cable in the middle of no where
Post by: johnny on March 08, 2020, 09:04:41 PM
greetings...

once i hooked a bungee to the clutch arm by the exhsust... pulled on it to change gears... that is when i made the kit... and now carry the kit and a spare oe...

rode all the way from johnston ridge observatory at mt st helens to hillsboro... 130 miles... 2up... tugging on the bungee...

if you wanna take the cable out of the jacket you can just tug on the cable... look... take a deep breath... step away... figger it out... go getts something you can tug on...

j o
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 09, 2020, 05:51:48 PM
Hey, sorry about the radio silence my phone died and I camped out last night. I got the clutchless gear shift down and have put about 30 miles behind me, I tried using the pulley method when it happened but the lever is tighter then hell, or I wasnt pulling on it hard enough. Any ideas why that might be? Did I possibly burn out the clutch somehow?
Title: Re: Broken clutch cable in the middle of no where
Post by: volador on March 09, 2020, 05:59:05 PM
Quote from: evanwellsk75 on March 09, 2020, 05:51:48 PM
Hey, sorry about the radio silence my phone died and I camped out last night. I got the clutchless gear shift down and have put about 30 miles behind me, I tried using the pulley method when it happened but the lever is tighter then hell, or I wasnt pulling on it hard enough. Any ideas why that might be? Did I possibly burn out the clutch somehow?

You smell any smoke? From the clutch I mean? If not pull on that pulley harder
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 09, 2020, 06:07:10 PM
I havent smelled anything abnormal, I burnt out a clutch before by accidentally over tightening it so I was checking pretty frequently on any acrid smells coming from it. Though I just tried again, hard as a rock. Im starting to think this might be a larger problem than just the cable?
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 09, 2020, 06:20:43 PM
Op! Sidestand was the issue. Wire and screw clamps here I come!
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 09, 2020, 06:44:45 PM
Thanks for these updates. Keep them coming. 112350
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 10, 2020, 03:12:28 PM
Still stuck in santa rosa, no hardware stores seem to have these hillman fasteners so im calling around to repair joints to see if theyd let 2 go. As of now no luck
Title: Re: Broken clutch cable in the middle of no where
Post by: Martin on March 10, 2020, 04:23:45 PM
I've been carrying a spare clutch cable for the last 20 plus years. It's been used twice, but not on my bike. I do have a tendency to carry a pretty good selection of spares. To be honest besides a couple of flat tyres and the two times I had to use the test light nothing else has been used on my bike. Murphy's Law number 221 is nothing you carry will ever fail. Not shown is spare throttle and clutch cable and a newly added HES. The AM/FM radio has been replaced with wireless ear phones linked to my GPS helmet lock and cable has been replaced with a more compact version.
Regards Martin.

* Tools in tail.png (61.06 kB . 768x576 - viewed 472 times)
* Tools in Topbox.png (52.09 kB . 768x576 - viewed 456 times)
Title: Re: Broken clutch cable in the middle of no where
Post by: koapono on March 10, 2020, 05:32:34 PM
when you buy replacement cable, buy two.
run the "spare" alongside the new one, grease up the exposed parts and wire-tie the ends out of the way.
you'll never snap another cable again, provided you lube the ends once a year or so.
Title: Re: Broken clutch cable in the middle of no where
Post by: volador on March 10, 2020, 06:01:32 PM
more like

 [ Invalid Attachment ]
Title: Re: Broken clutch cable in the middle of no where
Post by: Martin on March 10, 2020, 06:20:12 PM
I always lube all my cables with a PTFE lubricant which is compatible with the Teflon lined OEM cables. Some non PTFE based lubricants are not compatible and will actually degrade the lining faster than applying no lubricant at all. WD40 is not a cable lubricant.
Regards Martin.
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 10, 2020, 06:25:53 PM
Got a used one off a fella here in santa rosa, as far as an emergency kit goes. I had one but decided to store it away in Denver for the winter while I was over seas. Didnt think Id be touching the bike again, but I didn't have a spare clutch cable in that either. Definitely gonna add it when I collect all my things once again.
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 10, 2020, 08:55:07 PM
Hey so I installed the cable, all is seemingly alright though is doesnt seem like the clutch is engaging fast enough- it feels loose (it wont engage until the lever is almost all the way out). Il walk through my procedure and maybe someone can tell me where I screwed up.
I installed it along roughly the same path as the old one (I couldnt get the metal tube end on the handle side through a piece between the radiator and frame so I went over it.
I lubed up the handle side barrel point. (This is surely why I snapped it in the first place)
I slacked the handle side all the way then adjusted until I had 2.96 in on the lever near the transmission.
I then tightened the transmission adjust bolt just until I had resistance, then stopped.
I readjusted the handle side adjustment screws.

And here I am. It works, but It makes me nervous on hills and for longevity for the clutch.
Title: Re: Broken clutch cable in the middle of no where
Post by: johnny on March 10, 2020, 09:19:08 PM
greetings...

is this moto oe or delooped...  poast up some photos of this moto and include the clutch lever mechanism at the handlebar...

j o
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 10, 2020, 09:35:27 PM
Here ya are johnny
Title: Re: Broken clutch cable in the middle of no where
Post by: Martin on March 10, 2020, 09:44:48 PM
You can by this tool off Tills or make one out of a piece of 75mm box.
Regards Martin.
 [ Invalid Attachment ]  [ Invalid Attachment ]
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 10, 2020, 09:57:25 PM
Hey martin thanks, ive fashioned something similar out of some wire
Title: Re: Broken clutch cable in the middle of no where
Post by: volador on March 10, 2020, 09:59:21 PM
Looking good. It is measuring tool for the 3 inches/75mm at the clutch arm/lever
If you have a doubt here is the procedure

http://www.motobrick.com/index.php/topic,13203.msg117628.html#msg117628 (http://www.motobrick.com/index.php/topic,13203.msg117628.html#msg117628)

Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 10, 2020, 10:08:15 PM
Right right, smart way to measure around the grommet. Its all well and good, ive measured it a half dozen times now and still the clutch doesnt engage, though theres little freeplay and its quite hard to pull in. I lubed it up some more and its easier to pull in. 
Title: Re: Broken clutch cable in the middle of no where
Post by: evanwellsk75 on March 11, 2020, 12:51:46 AM
Yeah I have zero free play in my handle bar lever, Ive tried adjusting it both at the handle bar and tranny case. Does this make any sense? The cable came off a k100 so my only thought is maybe its sized differently or the cable was already pretty stretched. But that doesnt really explain the lack of slack coupled with the minute friction zone.
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 11, 2020, 01:03:57 AM
If your moto has an RT handlebar and that cable is from a stock RS, that could be a problem. Does the cable have some slack? If the cable is too long, that could also cause binding in lever action. You seem to be able to set free cable length so things might be ok.
(http://www.motobrick.com/gallery/2/1601-110320005406.jpeg)

Here's how I do a basic clutch adjustment on my K75.
Clutch cable routing affects ease of pull. Move it around to determine if the pull improves. Lubrication of the clutch arm affects ease of pull. Corrosion might be at play. Oil the pivot if you can.
Title: Re: Broken clutch cable in the middle of no where
Post by: beemuker on March 11, 2020, 09:07:42 AM
all this clutch cable talk has me thinking of putting a spare on the brick. max wants $50+, what about this aftermarket one on fleabay
https://www.ebay.com/itm/BMW-CLUTCH-CABLE-K75-K75-C-S-K100-K100RS-K1-Made-by-Venhill-USA-Dealer/222485236799?hash=item33cd274c3f:g:y7oAAOSw~gRVx5yP

best option?
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 11, 2020, 09:25:27 AM
Quote from: beemuker on March 11, 2020, 09:07:42 AM
all this clutch cable talk has me thinking of putting a spare on the brick. best option?
According to tribal lore, just carrying any spare cable is insurance that you won't need it. I've read some good forum reviews of Venhill cables. The ad indicates they'll fit low bars. I'd ask the vendor for tip-to-tip measurements.
Title: Re: Broken clutch cable in the middle of no where
Post by: The Mighty Gryphon on March 11, 2020, 09:40:57 AM
From what I have learned doing graduate work at the school of hard knocks is that the only spare parts that prevent failure are expensive OEM. 

There are stories about that aftermarket cables are not as reliable as OEM.  An unreliable cable will not prevent the cable on the bike from breaking. 
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 11, 2020, 10:25:30 AM
Quote from: The Mighty Gryphon on March 11, 2020, 09:40:57 AM
An unreliable cable will not prevent the cable on the bike from breaking.
Now there's shamanic lore from an irrefutable source.  112350
Title: Re: Broken clutch cable in the middle of no where
Post by: beemuker on March 11, 2020, 11:37:45 AM
so string and / or bailing wire is out?
Title: Re: Broken clutch cable in the middle of no where
Post by: beemuker on March 11, 2020, 11:42:47 AM
Quote from: Laitch on March 11, 2020, 09:25:27 AM
According to tribal lore, just carrying any spare cable is insurance that you won't need it. I've read some good forum reviews of Venhill cables. The ad indicates they'll fit low bars. I'd ask the vendor for tip-to-tip measurements.

New message from: ocd_machine Top Rated Seller(1,908Red Star)
Approximately 59 3/4 inches, stock size.

Best regards,
Lyn
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 11, 2020, 11:52:46 AM
Stock S cable is 1510mm; Venhill is 1518mm so it's in the ballpark for length and it's Teflon lined, too. If you use it, please review it.

Title: Re: Broken clutch cable in the middle of no where
Post by: beemuker on March 11, 2020, 12:49:31 PM
Quote from: Laitch on March 11, 2020, 11:52:46 AM
Stock S cable is 1510mm; Venhill is 1518mm so it's in the ballpark for length and it's Teflon lined, too. If you use it, please review it.
I’m going to get it as a spare and hope not to need it but you never know
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 11, 2020, 12:58:55 PM
Quote from: beemuker on March 11, 2020, 12:49:31 PM
. . . but you never know
evanwellsK75 probably wouldn't dispute that.
Title: Re: Broken clutch cable in the middle of no where
Post by: Martin on March 11, 2020, 02:05:42 PM
I've seen the nipples pull off on non OEM cables. A mate who used my spare when his non OEM cables nipple came off wanted to replace it with a Venhill I declined. A mate of a mate tried the same thing wanted to use my spare and replace it with a Venhill, I declined and he had the longer cable anyhow. I found this site on cable reviews a bit of a mixed bag https://www.amazon.com/Venhill-U01-1-100-BK-Universal-Motorcycle-Clutch/product-reviews/B00O1C26SW
Regards Martin.
Title: Re: Broken clutch cable in the middle of no where
Post by: beemuker on March 11, 2020, 02:25:37 PM
Quote from: Martin on March 11, 2020, 02:05:42 PM
I've seen the nipples pull off on non OEM cables. A mate who used my spare when his non OEM cables nipple came off wanted to replace it with a Venhill I declined. A mate of a mate tried the same thing wanted to use my spare and replace it with a Venhill, I declined and he had the longer cable anyhow. I found this site on cable reviews a bit of a mixed bag https://www.amazon.com/Venhill-U01-1-100-BK-Universal-Motorcycle-Clutch/product-reviews/B00O1C26SW
Regards Martin.
Oh well I already ordered it but going to use it as a spare hopefully if my original breaks it at least get me home without having to clutchless shift it
Title: Re: Broken clutch cable in the middle of no where
Post by: Martin on March 11, 2020, 02:44:41 PM
My OEM cable is coming up to it's 28th birthday. The key to long cable life is make sure the routing is correct, lube the cable with a PTFE lube, fit a grease nipple to the clutch arm, grease the nipples at both ends, grease the wear points on the lever, and make sure the clutch lever is not worn and catching on the cable. The reason I declined the Venhill swap was they were half the price of an OEM cable, and I had at that point never replaced a OEM cable on my bike. However last year I did have to replace my 27 year old throttle cable.
Regards Martin.
Title: Re: Broken clutch cable in the middle of no where
Post by: BlitzenGruv on March 13, 2020, 01:28:17 AM
There's another time-tested solution: carry a spare cable when riding long distance! We used to coil it up inside the headlight shell. But, as much trouble as it is to get the headlight outta these bikes you must find another place.
Title: Re: Broken clutch cable in the middle of no where
Post by: Laitch on March 13, 2020, 01:47:22 AM
Quote from: beemuker on March 11, 2020, 02:25:37 PM
Oh well I already ordered it but going to use it as a spare hopefully if my original breaks it at least get me home without having to clutchless shift it
If you don't have confidence using the cable you just purchased as a spare, I suggest you install it when you receive it and use your current cable as a spare. That would serve two purposes. You'd be able to review its fit and performance for us and you would insure having a proven working spare cable for yourself.
Title: Re: Broken clutch cable in the middle of no where
Post by: volador on March 13, 2020, 03:24:20 AM
As magical as a unicorn, a few drops of PTFE silky smoothness. For all your clutch cable lubrication needs, use on a regular basis. It is just a wonderful product.

(http://www.motobrick.com/gallery/2/5332-130320024919-2847152.jpeg)
Title: Re: Broken clutch cable in the middle of no where
Post by: Martin on March 13, 2020, 04:02:45 AM
While working for ESSO in the mid 1980's I was given a can as a trial. I had a sticky Rollador on my garage so I sprayed the runners. On the first lift it shot all the way to the top with no effort. I now only use it on cables, it is just about on it's last legs and I'll have to buy a new can. Really good stuff I've been using on my Brick cables for over 20 years.
Regards Martin.