Another Victim of Clutch Cable

[sun_bill1974]

I am the most recent victim to clutch failure....I was riding around locally, and heard the clutch cable snap ...and all of a sudden, no resistance when I pull the clutch in. Thank god I wasn't too far from home, but I did blow through two red lights so the bike wouldn't stall. Called the dealer right away, and they'll hopefully pick-up the bike sometime next week.
O.k., so here's my question: clearly this is a common problem with bdm from all the reading from this forum, so why not switch to a stronger cable instead of spending money to honor your warranties? I understand different riders will have different wear and tear, but I could genuinely say I only use the clutch when I have to...I never use it for breaking. Anyhow, it is what it is...

 

[Fibersnake]

sun_bill,

I am not sure that the break on the clutch cables are that much more in precentage with the BDM than any others. Granted there has been many recent post of some breaking including mine. That said the cable they use are Barnett and are very good cables.

Not sure how many miles you have on yours or your riding style, but for me it was 17-18k and to be honest with the riding I do, with much of it on back roads, did not see it has unusal. PITA yes but nothing unusal, just bad timing.

Where did yours break BTW? Also have you been keeping up on the maintenance on it including the lube of the internal cable sheathing. Combine that with IMHO a fairly high pressure clutch and allot of stress, I would expect these to be more suceptable to breakage than say one on a Honda 450?

Glad to hear you made it home alright, and it would not be a bad idea to get you a spare along with the replacement for the future, just to save the downtime since there is not 1 standard for the BD.

Oh I did find a solderless ferrual in my stock of stuff that is used for connecting control rods on RC Helicopters that fit on the clutch end where mine broke. Tested it out and the damn thing works and I could probably go out and ride. Will hold off though since got a replacement is one the way and would be much more reliable. That said, I am going to throw the ferrual in my tool bag and keep in case I have another break on the road at the clutch end ferrual. May save me from the roll and shift or a tow job!

Good luck on getting your up soon and if nothing else, it provides a perfect opportunity to grease up the clutch ramp and balls, make a clutch adjustment, etc. I am also taking the opportunity to inspect the plates, adjust the primary and in my case even peak inside the tranny through the top cover to get basic inspection off gears.

 

[Mickeetwo]

Fiber....this would be a good time to post a How-to on the clutch cable replacement ....could be helpful for some of us down the road.

 

[mimbler]

Fibersnake, could you post exactly what solderless ferrile is (i.e. part number and manufacturer)? I've not heard of that bit of hardware, but I'd like to get one and toss it in my tool bag. I've finished a couple of rides with a broken clutch cable and they weren't fun,
thanks, Mike

 

[woodbutcher]

probably different for each model and possibly year bike, so one size don't fit all

 

[sun_bill1974]

FS, I currently have about 2,100 miles on my bike, its an 07 K-9, and I wasnt' aware there is continual up-keep even after my 1000 mile service...again, I don't ride hard on the bike, escpecially with all the noise with regards to the sensitivity of the engine and clutch. The only maintenance is checking the bike every week for anything out of the ordinary...I find the wiring on the vehicle was poorly done, I'm constantly wrapping electrical tape, or rubber around certain wires that seem to be sticking out...
I certainly don't expect this to perform like my HD, but I expected more than 2100 miles before the clutch snapped. I wish I was more handy where I was confident with taking the tranny apart, but I'm not...one of these days hopefully.

sun_bill,

I am not sure that the break on the clutch cables are that much more in precentage with the BDM than any others. Granted there has been many recent post of some breaking including mine. That said the cable they use are Barnett and are very good cables.

Not sure how many miles you have on yours or your riding style, but for me it was 17-18k and to be honest with the riding I do, with much of it on back roads, did not see it has unusal. PITA yes but nothing unusal, just bad timing.

Where did yours break BTW? Also have you been keeping up on the maintenance on it including the lube of the internal cable sheathing. Combine that with IMHO a fairly high pressure clutch and allot of stress, I would expect these to be more suceptable to breakage than say one on a Honda 450?

Glad to hear you made it home alright, and it would not be a bad idea to get you a spare along with the replacement for the future, just to save the downtime since there is not 1 standard for the BD.

Oh I did find a solderless ferrual in my stock of stuff that is used for connecting control rods on RC Helicopters that fit on the clutch end where mine broke. Tested it out and the damn thing works and I could probably go out and ride. Will hold off though since got a replacement is one the way and would be much more reliable. That said, I am going to throw the ferrual in my tool bag and keep in case I have another break on the road at the clutch end ferrual. May save me from the roll and shift or a tow job!

Good luck on getting your up soon and if nothing else, it provides a perfect opportunity to grease up the clutch ramp and balls, make a clutch adjustment, etc. I am also taking the opportunity to inspect the plates, adjust the primary and in my case even peak inside the tranny through the top cover to get basic inspection off gears.

 

[Fibersnake]

FS, I currently have about 2,100 miles on my bike, its an 07 K-9, and I wasnt' aware there is continual up-keep even after my 1000 mile service...again, I don't ride hard on the bike, escpecially with all the noise with regards to the sensitivity of the engine and clutch. The only maintenance is checking the bike every week for anything out of the ordinary...I find the wiring on the vehicle was poorly done, I'm constantly wrapping electrical tape, or rubber around certain wires that seem to be sticking out...
I certainly don't expect this to perform like my HD, but I expected more than 2100 miles before the clutch snapped. I wish I was more handy where I was confident with taking the tranny apart, but I'm not...one of these days hopefully.

Sun_bill,

In your case, that is beyond reason to have it break as such a low mileage and following a 1000 mile service only 1100 miles ago. Can understand the frustration for sure. Not much more that I can offer other than wishes for a quick repair and more reasonable wear in the future.

What are the wires that you refer to that are sticking out BTW. Also where you able to get with a shop to see about having the speedometer taken care of with the sticking needle?

 

[sun_bill1974]

FS,
If I look into the wiring components of the bike (from the side of the air-filter), I could see many of the internal copper wires are held together by a large rubber, and that rubber is beginning to wear and tear...exposing the copper wires. That is what I'm constantly wrapping up with electrical tape....
I too hope to be back on the road very shortly....I will keep everyone posted as this situation progresses...hopefully in a right direction.

 

[Fibersnake]

Fibersnake, could you post exactly what solderless ferrile is (i.e. part number and manufacturer)? I've not heard of that bit of hardware, but I'd like to get one and toss it in my tool bag. I've finished a couple of rides with a broken clutch cable and they weren't fun,
thanks, Mike

Unfortunatley I can not sicne the one I had was in the spare parts box and were original intended for linkage and cables for R/C Aircraft.

I am hoping to stop by the R/C shop and see if I can finds some better ones and if I do, I will be sure to post the info here.

The stock ferrual on mine is .252" OD and the cable is .094" OD.

The one I used is something like this:

Barrel Nipple WRN-002

 

[MARV]

Barrel Nipple WRN-002

thats basically the same type ferrel used to modify the cable length when using the PSI carb. the cable slips thru then held with a set screw.

 

[Fibersnake]

Actually this would be a better example

Abbatron Online Catalog

It is listed as a shaft coupling.

These may work also and I am going to order a set of 4 to see if they fit even better. The one I used is a little longer and uses two set screws plus little loose in the ball.

86675 - Stop Collar Set