"Broken Clutch Cables and Repairs"

[bob109]

Folks:

After breaking my clutch cable yesterday I was hell bent on getting the 9 back on the road as it's Bike Night and I wasn't going to miss out on a nice 85 degree evening :D

Decided to repair the stock cable rather than get a replacement from the dealer! That according to some has been a long ordeal and I have little patience with dealers and their BS!

First thing about the cable break is that it occurred on the lower end of the cable! You'll have to forgive the clarity of the pic but if you look close you'll see approximately 1 inch of cable protruding from the end of the rubber booth. That end is suppose to have the round steel ferrel! The cable pulled out of the ferrule!!!!! The cable itself was barely frayed!
http://image1.frappr.com/pix1/i/20070524/e/d/b/edb4a340d6cb327e17fb45af64291dbe0_large.jpg

I had to remove the cable bracket and clutch lever to get enough slack to rework the end of the cable. This photo shows how the end of the cable frayed when it pulled from the ferrule! The cable end was eventually Silver Brazed and the very end had to be trimmed with cutting snips so a new ferrule could be brazed on! I had to strip off approximately 1.5 inches of plastic coating from the cable before any heat was applied!
http://image1.frappr.com/pix1/i/20070524/a/e/2/ae234d9b2ef77832fb1201761bf872030_large.jpg

The stock ferrule was not brazed to the end of the cable from the factory! That is where the problem with broken clutch cables is occurring. This is a pic of the stock ferrule. The cable is simply inserted into a hole in the ferrule and it is pressure crimped on the end of the ferrule! This is not a good design in my opinion. Dip Brazing should have been the method used to secure the ferrule to the cable end :bigthumbsup: With that in mind I made a new steel ferrule from a piece of .238 dia. round stock ( it was actually a door hinge pin ). I drilled a .099 hole completely through the ferrule as I wanted to be able to Silver Braze the entire end of the cable to the ferrule!
This is the stock ferrule with the dimple on the end!
http://image2.frappr.com/pix2/i/20070524/3/d/d/3ddf5ee71e4e710b788af062312803bf0_large.jpg

This is the stock ferrule, plastic bushing and the .238 dia. hinge pin I used for the new ferrule!
http://image1.frappr.com/pix1/i/20070524/d/d/a/dda2708c5aab7531b837816137f1f0610_large.jpg

I drilled the .099 hole in the hinge pin after center punching it and then cut the new ferrule to length to match the original!
http://image1.frappr.com/pix1/i/20070524/9/8/d/98df0d9e2c792f44b033a1fd53c509b50_large.jpg
The new ferrule is on the left, the old on the right!
http://image2.frappr.com/pix2/i/20070524/3/f/9/3f919e4a5a981929cb860049501796c20_large.jpg

I used Grade 4 Silver Solder for both tining the cable and brazing the new ferrule to the end of the cable. Used a Jewlers File to clean up the end of the cable where it protruded through the ferrule!
http://image1.frappr.com/pix1/i/20070524/0/d/f/0df6d3da07361d2f0cdd11fd8a415b900_large.jpg
Reassembled all the components and adjusted the clutch lever and it works like a champ :bigthumbsup: Unfortunately I'll probably have to do the other ferrule whenever that pulls loose as Suzuki used the crimping method on both ends of the cable :(

[JUtah]

Very cool you were able to fix it!
I think I would have made the dealer give me a new cable just out of GP... Then if it ever does break you have a spare.
:D

[marauder]

My cable broke in the exact same spot last week repaired it the same way been riding ever since no problem but i do have a new one on the way

[bob109]

Very cool you were able to fix it!
I think I would have made the dealer give me a new cable just out of GP... Then if it ever does break you have a spare.
:D
Unfortunately the bike is out of Warranty :(

[bob109]

My cable broke in the exact same spot last week repaired it the same way been riding ever since no problem but i do have a new one on the way
:bigthumbsup:

[rasputin]

Well done Bob..nice job!

[Delmustator]

Sounds like DLP should carry some correctly made cables...

Bet they would sell them without any problem..

[bob109]

Sounds like DLP should carry some correctly made cables...

Bet they would sell them without any problem..
Ask and you shall receive :D
DLP has them avilable :bigthumbsup:
http://www.directlineparts.com/product.asp?pid=6911&str=290&ID=463058641

[biker-chicky]

I wish the pics worked on this post Dammm, can anyone else see the pictures or is it just my computer?

[Delmustator]

I wish the pics worked on this post Dammm, can anyone else see the pictures or is it just my computer?


No picture, or link to an external picture....

[silentrider]

Did Your Clutch cable show signs of Wear, Like Lamonsters Did From the Motor Mount?

Just wondering :confused: if so how many miles do you have on your bike Thanks :bigthumbsup:

[biker-chicky]

Did Your Clutch cable show signs of Wear, Like Lamonsters Did From the Motor Mount?

Just wondering :confused: if so how many miles do you have on your bike Thanks :bigthumbsup:
no, the nib on the bottom end broke clean free, I'm lucky I wasn't down gearing into a hot corner of passing a huge truck, it happened after all that fun in the drive way when I had to start it up to park it in a diffrent spot. Honestly I don't know what I would have done if the failure happened while I was in motion, Yikes!! :o I would have been lost for what to do I would have hit the kill switch and costed her off to the side of the road. but man it would have been hell. I thank the Lord for any angles that was with me yesterday and I did a 1 and ahalf hour loop by myself as well that day.

[Delmustator]

I think the clutch cable failures should be reported also. That is a safety hazard as well. I plan to replace mine with one from DLP soon.

[bob109]

I wish the pics worked on this post Dammm, can anyone else see the pictures or is it just my computer?
Frapper is back up and running so you should be able to see the pics :bigthumbsup:

[biker-chicky]

Frapper is back up and running so you should be able to see the pics :bigthumbsup:
cool ya they work now supper, ya that flipping nib broke on mine , just like in the pics. Good pics Thanks for posting bob109

[57plus]

Nice job and it looks like you did it better than the factory. I've seen this problem on different machines for over forty years. You'd think the manufacturers would get it right after that long.

[biker-chicky]

Nice job and it looks like you did it better than the factory. I've seen this problem on different machines for over forty years. You'd think the manufacturers would get it right after that long.
ya you got that right, it is amazing that with our heavy clutch and all the extreme ridding this bike is able to provide and the thought and close call of loosing my clutch especially when I use it as a safety thing and the fact that the insurance ICBC guy says to me "If I'm feeling like I'm going to fast into the corner pull the clutch in and use your back brakes not your fronts, well how the hell am i going to use the clutch if this happened Yikes, last minute decisions are hard to do when you hot in the corners, especially being a fairly new rider. DAMMM, I will fill out one of those reports, and also call ICBC here and tell them about this very feeble cable and maybe something will change for the better this bike is way to powerfull for such a lame cable nib. I would rather pay the extra 50 bucks on the retail amount to ride knowing something so important isn't going to fail so abruptly and with no warning or signs of up and coming failure. It is diffrent if it was a periodic maintenance service neglect, but this a person wont see signs it is about to go during one of those services. Also they dont even stock them LOL not a single one in all of canada when I had called the dumb numm nuts!! oh and the part is all of about 35 dollars :yikes: Man oh man its got to be the cheepest stock part available !!! :swear:

[neverenoughtime]

I think the clutch cable failures should be reported also. That is a safety hazard as well. I plan to replace mine with one from DLP soon.


I ordered the clutch cable from DLP today. Looks like a whole lot better piece(from the pics I have seen) than the factory cable.

[IAH109R]

I ordered the clutch cable from DLP today. Looks like a whole lot better piece(from the pics I have seen) than the factory cable.


Welcome to back order land.. I've had mine on back order since 8/30. Estimated ship date is 10/19 as of today.

[bob109]

I ordered the clutch cable from DLP today. Looks like a whole lot better piece(from the pics I have seen) than the factory cable.
The Barnett Clutch Cable is worth every penny. It is a heavy duty cable with floating barrels so there's virtually no cable twist/torque exerted on the cable with each pull of the clutch lever :bigthumbsup:
http://image1.frappr.com/pix1/i/20070720/8/b/a/8ba536f39ce356623d81bc8fc023d8710_large.jpg

[biker-chicky]

The Barnett Clutch Cable is worth every penny. It is a heavy duty cable with floating barrels so there's virtually no cable twist/torque exerted on the cable with each pull of the clutch lever :bigthumbsup:
http://image1.frappr.com/pix1/i/20070720/8/b/a/8ba536f39ce356623d81bc8fc023d8710_large.jpg
thanks for the pic and wow this is a supper strong looking part has anyone every had one of these brake on them, does it have a life time warranty, or is the clutch cable braking /nibs coming off a commen thing ? should I always carry a spare nib even with one of these?

[biker-chicky]

after looking at this is it possible to attach another nib under the clutch attachment place so it can be there as like a fail safe? seems to look like there is enough room to have 2 nibs? One in the cradle and one underneath some how? so if the one in the cradle comes loose the one underneath will at least hang on long enough to make a better repair? hmm this clutch cable thing doesn't seem high tec to me and I see this gear changing mechanism should look more like a U joint instead of this old fashion nib thing. Oh maybe one day someone will come up with a better design and one small enough to fit, I'm sure there will always be a cable in there some place but man I don't like the idea of loosing my clutch, especially since I live in the mountions, Yikes!!

[JUtah]

after looking at this is it possible to attach another nib under the clutch attachment place so it can be there as like a fail safe? seems to look like there is enough room to have 2 nibs? One in the cradle and one underneath some how? so if the one in the cradle comes loose the one underneath will at least hang on long enough to make a better repair? hmm this clutch cable thing doesn't seem high tec to me and I see this gear changing mechanism should look more like a U joint instead of this old fashion nib thing. Oh maybe one day someone will come up with a better design and one small enough to fit, I'm sure there will always be a cable in there some place but man I don't like the idea of loosing my clutch, especially since I live in the mountions, Yikes!!


I think your worrying about it too much BC... only a few of the stock cables have broke... and Clutch cables have been around for a VERY long time... so I think the concept of how they are constructed is pretty sound overall... Zuk just had some bad parts that were probably cheaply made in China...

Order some Barnett's throw em on, and just make checking your clutch cable part of your periodic preventative maint.

[neverenoughtime]

Welcome to back order land.. I've had mine on back order since 8/30. Estimated ship date is 10/19 as of today.






Where did you hear that it was going to be October 19th? Mine is the extra 3" long what is yours? This sucks. Looks like I am going to be waiting a extra couple of weeks :-\

[IAH109R]

Where did you hear that it was going to be October 19th? Mine is the extra 3" long what is yours? This sucks. Looks like I am going to be waiting a extra couple of weeks :-\


Here is the e-mail notice I got. Mine was the standard length.

***DO NOT REPLY TO THIS EMAIL***

You have placed an order with Honda Direct Line/Direct Line Parts that
has at least one item that is out of stock. Below is a list of the
item(s) on backorder with an estimated ship date. These dates are
estimates provided by the manufacturer. These dates can change. We will
be sending this notice on a weekly basis to keep you updated as to when
your item(s) should ship. If you have any questions or would like to
make any changes please call us at 1-888-258-6699.




SKU Description
Est Ship Date

BTT-1027010109 M109R Clutch Cable,SS,Std 10/19/2007

[billym109]

Here is the e-mail notice I got. Mine was the standard length.

***DO NOT REPLY TO THIS EMAIL***

You have placed an order with Honda Direct Line/Direct Line Parts that
has at least one item that is out of stock. Below is a list of the
item(s) on backorder with an estimated ship date. These dates are
estimates provided by the manufacturer. These dates can change. We will
be sending this notice on a weekly basis to keep you updated as to when
your item(s) should ship. If you have any questions or would like to
make any changes please call us at 1-888-258-6699.




SKU Description
Est Ship Date

BTT-1027010109 M109R Clutch Cable,SS,Std 10/19/2007


i got the last one haha.... :joke:

[IAH109R]

FYI.........


I just got notice today that my cable shipped.

I've decided I am going to install the new cable but leave the old one in place (tie it to the new cable) and coil it up out of the way just in case I run into an unexpected cable failure down the road.