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Discussion Starter #1
5560 miles and my clutch cable frayed....luckily it didn't break completely...first noticed a problem when I couldn't shift to second....after I pulled over I realized the clutch wasn't disengaging completely. Been meaning to buy a back up.... Murphy's law...didn't expect it to go so soon. Lubed it regularly too..

Doubt I'll get one locally hope cheap cycle parts can get it to me quickly....two actually.
 

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I got one from them and it took 2 to 3 days to california.
 

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I had to replace my original cable around that mileage too.
The replacement that came from ma Kawi. was different than the original.
There was a steel or metal of some sort, sheathing over the round end stop that fits to the lever. It has a loose fit and allows for more free movement I believe.

Did the one you just broke have this "sheath" around it?
If so I'll be ordering another in advance myself.:cheers:

And :thanx:
 

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Discussion Starter #4
Yes I believe it does...I noticed that when I was inspecting the frayed end.
 

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I am wondering if a damaged it the last time I lubed it. I had a little trouble disengaging it from the lever...
 

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Damaging a cable is hard to do. I pulled and lubed my throttle cables and clutch cable yesterday. Looked good as new on my '08 (which is new to me). One thing I noticed was that the clutch cable ball end had a metal sleeve of some sort. I don't see that as a part looking at the parts fische for the lever or the cable. Maybe you should have one and don't?
 

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Discussion Starter #9
Mine did have the metal sheath on the handle end....

Couldn't find one locally...called every Kawi dealer in a 2 hour radius...

Ordered two from Cheap Cycle parts may be here by Friday....hopefully I can save the weekend.

Mine looked brand new as well.....until it broke....
 

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Couldn't find one locally...called every Kawi dealer in a 2 hour radius...

Mine looked brand new as well.....until it broke....
That sux. A trick I learned (but never had to use) was to zip tie the extra cable to the existing cable. If the existing one breaks again, your spare is right there, routed and ready to go.
 

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Discussion Starter #11
That sux. A trick I learned (but never had to use) was to zip tie the extra cable to the existing cable. If the existing one breaks again, your spare is right there, routed and ready to go.

yup that's why I ordered two....I planned on doing this but figured I had a little more time....guess not...
 

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Sounds like either the part was defective, or damaged somehow, or something in the routing was causing it to rub the wrong way, IMO. I've got about 52k miles on my original with no problems, (though I've been touring with a spare for the last 17k miles in anticipation of an eventual break).
 

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Lube, Lube, Lube.

I hit mine with same thing I do my chain with, every time I do my chain, about every other fill. 30k on the first chain, 30k on the first and only clutch cable.

Machog
 

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When you guys adjust your clutch cable up top make sure you try and point the slot away from straight up. That way no water gets into your cable. I know this may not allow you to adjust the slack exactly where you want it but pointing the slot away from straight up helps cable life for sure.
 

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15000 Miles, never lubed it. Might lube it at some point. Just going to grab a second one at around 20k to carry around.
 

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Discussion Starter #17
New cable should arrived tomorrow....so I can ride this weekend...of course its suppose to rain now :(

I am pretty sure my cable got damaged from taking it out of the clutch handle to lube it. Any lateral bending will weaken the cables where they connect to the ball. Mine was always a bit tight getting it out...I'm NOT going to lube this one....its probably better to leave it alone unless it gets gunked up or shows corrosion. The throttle cables never get lubed and they hold up just fine....
 

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I squirt Teflon chain lube on the cable end and pivot every few hundred miles. I turn the slot up, and turn it back when done. No actual disassembly
 

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Almost ruined my weekend. Some friends and I had a cabin in Robbinsville,NC for the weekend. Saturday I feel my clutch cable start to go. It was 4:30pm, I called Wheelers, who is just south of the Tail of the Dragon(129) He told me they didn't have a cable for a Versys but to bring it in and He'll try and find something to fix it. After looking through a stack of cables from other bikes, He found one that would work. $25 later I was on my way. Thanks Wheeler, for being fair with the price and not sticking it to me.
 

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Discussion Starter #20
I found a trick that makes removing the clutch cable very easy. After loosening the adjustments both at the handle and the clutch I disengage the clutch using a Quick-Gip

Bar clamp....It gives the cable plenty of slack so its very easy to disengage the ball from the handle...
 
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