clutch cable snaped - Kawasaki Versys Forum
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post #1 of 33 (permalink) Old 12-02-2009, 02:22 PM Thread Starter
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clutch cable snaped

my clutch cable just broke, how can i fix it. it broke off right at the point that is inserts into the "nipple" that connects it to the clutch handle. ill go try to take a pic or two and show yall a little better. Please help this is my daily driver!!
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post #2 of 33 (permalink) Old 12-02-2009, 02:37 PM
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Is this a for real question?
Unless you have a solder pot and new cable ends you can't fix it yourself.
Some shops (mostly independent ones) have these necessary parts and tools.
If it is under warranty take it to the dealer otherwise buy a new one and install it as per instructions in the factory service manual which you can find and download from this site.
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post #3 of 33 (permalink) Old 12-02-2009, 02:44 PM Thread Starter
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kinda what i thought thanks.
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post #4 of 33 (permalink) Old 12-02-2009, 03:40 PM
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25 bucks ...just put a new one on
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post #5 of 33 (permalink) Old 12-02-2009, 10:02 PM
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Keeping the cable lubed in the future will help it last longer.
Less friction = less tension.
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post #6 of 33 (permalink) Old 12-03-2009, 04:25 AM
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I notice my clutch cable around the clutch level make noise and needed to be lube very often (very 200 miles or so)

I am using WD40 currently... I might try the blue teflon stuff that I used on the chains next time...

Just wondering what everyone else is using to lube the clutch cable?

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post #7 of 33 (permalink) Old 12-03-2009, 07:06 AM
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Using my chain lube for the clutch cable.
Shatrat is right on Less friction = less tension = last longer.
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post #8 of 33 (permalink) Old 12-03-2009, 08:25 AM
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Quote:
Originally Posted by LAVersys View Post
I notice my clutch cable around the clutch level make noise and needed to be lube very often (very 200 miles or so)

I am using WD40 currently... I might try the blue teflon stuff that I used on the chains next time...

Just wondering what everyone else is using to lube the clutch cable?
You can buy cable lube at any decent bike shop. Also a good idea is the little jig that fits around the cable, to which you attach the can of lube and spray until you see lube coming out the other end of the cable housing. That way you know the whole cable has been lubed, not just the top couple of inches. I wouldn't recommend chain lube because many of those lubricants dry with a waxy film.
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post #9 of 33 (permalink) Old 12-03-2009, 09:33 AM
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Quote:
Originally Posted by Mt. Versuvius View Post
I wouldn't recommend chain lube because many of those lubricants dry with a waxy film.
Isn't that waxy film the lubricant itself?



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post #10 of 33 (permalink) Old 12-03-2009, 09:50 AM
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Isn't that waxy film the lubricant itself?
I don't know, I guess so. Chain lube is formulated like that to keep it from flinging off the chain at speed. In a cable housing though, you want a lubricant that flows so that it will travel the length of the housing. That's why chain lube isn't a good choice.
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post #11 of 33 (permalink) Old 12-03-2009, 10:21 AM
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chain wax works great on chains, controls, cables, what have you. yea, I can remember not having the $ to just buy a new cable...maybe fratedog will front you one .you can buy repair ends here and there and screw them on for the lever end, but the cable end, you'd probably have to get creative. necessity is the mother-in-law of invention.
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post #12 of 33 (permalink) Old 12-03-2009, 11:45 AM
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Quote:
Originally Posted by Mt. Versuvius View Post
You can buy cable lube at any decent bike shop. Also a good idea is the little jig that fits around the cable, to which you attach the can of lube and spray until you see lube coming out the other end of the cable housing. That way you know the whole cable has been lubed, not just the top couple of inches. I wouldn't recommend chain lube because many of those lubricants dry with a waxy film.
yeah I use one of those jigs, its called a plastic bag with the corner cut out to fit over the cable... fit the jig/plaggy bag over the cable, remake the bag seal to be oil tight, top up with oil of your choice and let it drip away to its hearts content.

BTW the clutch cable can be replaced without removing any panels.... having had this done when my clutch cable was found to be too stiff
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post #13 of 33 (permalink) Old 12-03-2009, 01:22 PM
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Clutch cable part number: 54011-0082
$16.91 from: http://partsfinder.onlinemicrofiche....e=13&A=72&B=52

Regular lubing helps, as does routing it better so it doesn't bind. (See post #15 with pics):
Clutch cable binding
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post #14 of 33 (permalink) Old 12-03-2009, 06:11 PM
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I rerouted mine. I had similar issues and replaced as well...mine did not break however. do a search on this site for rerouting. I've had no trouble w/ mine since and keep it lubed up as well. You can pick up a cable oiler that works nicely at any cycle shop or harbor freight.
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post #15 of 33 (permalink) Old 12-04-2009, 12:40 PM
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I had this issue a while back, and after reading this thread it reminds me I have to lube mine soon. When I installed the new cable, lubing with proper lubricant and applying through the MotionPro tool, I only routed it through the frame as needed to get to the clutch and left it free-of-restraint around the fork and the great plethora of other cables. Has improved feel.
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post #16 of 33 (permalink) Old 12-04-2009, 03:41 PM
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Dupont teflon lube that I use on my chain,also use it to lube every pivot point on the bike,works great

AMA EAA STN
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post #17 of 33 (permalink) Old 12-05-2009, 07:50 AM
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Originally Posted by maddjack View Post
Dupont teflon lube that I use on my chain,also use it to lube every pivot point on the bike,works great
+1 I do also. After every rain ride or wash I spray a bit in the cable, all pivot joints (pegs, levers and the pull at the clutch) and I spray a bit inside all the locks. The stuff is GREAT.
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post #18 of 33 (permalink) Old 12-05-2009, 03:25 PM
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Dupont's PTFE teflon lube is also a know neurotoxin, and should be used with caution.
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post #19 of 33 (permalink) Old 12-05-2009, 03:32 PM
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Quote:
Originally Posted by invader View Post
Dupont's PTFE teflon lube is also a know neurotoxin, and should be used with caution.
PTFE is fairly inert and non-toxic.
If it overheats it forms Perfluoroisobutene, but if your clutch cable is over 500 degrees you have other problems.
http://www.fluoridealert.org/pestici...ition.prod.htm
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post #20 of 33 (permalink) Old 12-05-2009, 04:12 PM
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That's good to know. Thanks for the highly informative link, Shatrat. As long as it's not sprayed onto hot exhaust and inhaled.

Quote:
Originally Posted by carter View Post
I rerouted mine. I had similar issues and replaced as well...mine did not break however. do a search on this site for rerouting.
I did supply a link. See post #15 with pics: Clutch cable binding
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