Thoughts on clutch cable failure

[Pat D]

Hey all- a few weeks back I posted about my clutch cable failing (I HATE when that happens far from home!) looking for recommendations on the most robust cable available. Turns out, the failed cable was a Motion Pro, which is what was recommended. I "think" this failure was an anomaly/factory defect- the crimped end nub at the clutch/engine end failed. The cable itself looks like the day I installed it, well lubed, the clutch worm/screw and rod are smooth like snot on ice. I can't see how I could have installed the failed cable incorrectly, but if anyone has any ideas, I'm all ears. As noted, a broken clutch cable is so irritating when far from home, I don't want the same thing to happen to the newly installed Motion-Pro cable if I can avoid it. Yes, I lubed the new cable when I installed it. Clutch operation is easy and smooth. 3rd pic is the handlebar end and the engine end after failure, 1st 2 pics are the end that failed.
Thanks for any insights.

 

[DogBunny]

That pic of the little broken piece -- the end of the twisted cable is supposed to be splayed out into it, i.e. the cable end is supposed to end in a mushroom head, and then the terminal is cast around it. The splayed cable end is called a rosette. Hard to tell from your pic, but I don't think the factory made the rosette. Hopefully just a one time defect -- would be bad news if the factory tooling was allowing this on a regular basis.

 

[joebgd]

Are you sure that's motion pro? . Could be my memory. That looks different from the one I installed years ago. Motion pro is my go to. I love em and trust them.
Edit, I don't remember my cable w that inside sleve?

 

[Mailman]

I don't remember my cable w that inside sleve?

I put a couple of those Motion Pro cables on and they had that plastic inner sleeve on the end by the engine. It’s placed up inside the cable sheath, in that photo it seems to have come loose and slid down.

 

[bosco659]

This makes me think that maybe I should keep a spare on the bike. It’s a fairly easy roadside fix and the spare cable could be easily stashed with a few zip ties. On a trip away from home, loading thr clutch would be disastrous.

 

[Its been a long time]

I agree, looks to me like faulty manufacture.

 

[AUTOMAN]

Hey all- a few weeks back I posted about my clutch cable failing (I HATE when that happens far from home!) looking for recommendations on the most robust cable available. Turns out, the failed cable was a Motion Pro, which is what was recommended. I "think" this failure was an anomaly/factory defect- the crimped end nub at the clutch/engine end failed. The cable itself looks like the day I installed it, well lubed, the clutch worm/screw and rod are smooth like snot on ice. I can't see how I could have installed the failed cable incorrectly, but if anyone has any ideas, I'm all ears. As noted, a broken clutch cable is so irritating when far from home, I don't want the same thing to happen to the newly installed Motion-Pro cable if I can avoid it. Yes, I lubed the new cable when I installed it. Clutch operation is easy and smooth. 3rd pic is the handlebar end and the engine end after failure, 1st 2 pics are the end that failed.
Thanks for any insights.

Show a few more pix of the fracture.

 

[gggGary]

I keep a lubed Motion pro hanging, ready to install.
pics of that.

spitballing; a travel range issue? ie something is stopping the clutch motion before you run out of cable pull?
Installed dozens, never had a problem.
I'm not much for carrying spares. I've nursed a no clutch vehicle home a time or two.
Note phone # etc motion pro seems stand up they may be interested in seeing the failure or be willing to stand behind it?

 

[5twins]

Besides lubing the inner cable, you also want to grease both ends ......

I also grease the exposed portion of inner cable. I'll admit, I'm a bit of a "grease fanatic", lol. Basically, I grease anything that moves, lol. Inside that left cover, I inject grease into the cable elbow with a needle tip on my grease gun ......

..... and I also grease the exposed portion of the clutch pushrod, and put grease on the portion of the shift shaft that turns in the cover.

 

[Pat D]

Show a few more pix of the fracture.

Unfortunately I have lost the broken off end bit in a fit of cleaning- I could get more pics of the cable itself.

 

[Pat D]

Besides lubing the inner cable, you also want to grease both ends ......

View attachment 359844

I also grease the exposed portion of inner cable. I'll admit, I'm a bit of a "grease fanatic", lol. Basically, I grease anything that moves, lol. Inside that left cover, I inject grease into the cable elbow with a needle tip on my grease gun ......

View attachment 359845

..... and I also grease the exposed portion of the clutch pushrod, and put grease on the portion of the shift shaft that turns in the cover.

I think you would endorse my lubrication protocols, though I'm not taking the cover off again just to take more pics. About the only thing I did not do is go to the cable with the needle adapter, but I will next time the cover is off.

 

[650Skull]

Never lost a clutch cable. Like Gary, I don't find that a problem always get the feel of any vehicle using a no clutch method, car or bike. Driven 100 miles in my car when the clutch shit itself.

Now a broken throttle cable is problematic. Not easy hanging one with one hand, (throttle has no resistance and wants to spin),, operating the throttle at the carb with the other hand whilst changing gears and looking at the road........

 

[Pat D]

Never lost a clutch cable. Like Gary, I don't find that a problem always get the feel of any vehicle using a no clutch method, car or bike. Driven 100 miles in my car when the clutch shit itself.

Now a broken throttle cable is problematic. Not easy hanging one with one hand, (throttle has no resistance and wants to spin),, operating the throttle at the carb with the other hand whilst changing gears and looking at the road........

40 years ago I could likely limp home with no clutch, I once had to get home 10 miles after breaking off the shifter on an old Kaw 175 stuck in 2nd gear, but the traffic and red lights have multiplied exponentially since those days. Did about a month with no reverse in a work truck once, that just took a little planning. Did another month with no starter, same deal, just took planning to set up the "drift". Cars with no clutch are easy if they're old school and don't have the stupid clutch/starter lockout (I disable every one I get)- most all of 'em will crank and start in low gear at a stop light- haven't figured out how to kick the ol' TX into starting from a red light 3 vehicles deep. Once I'm rolling it's no issue.

 

[bosco659]

Never lost a clutch cable. Like Gary, I don't find that a problem always get the feel of any vehicle using a no clutch method, car or bike. Driven 100 miles in my car when the clutch shit itself.

Now a broken throttle cable is problematic. Not easy hanging one with one hand, (throttle has no resistance and wants to spin),, operating the throttle at the carb with the other hand whilst changing gears and looking at the road........

Back when I was a kid, my friend broke the throttle cable on his cb350. He rode around for a while with a shoe lace tied to the linkage and would pull up on it to open up the carbs. We didn’t have much money back then.

Last summer the end of my shifter snapped off. I put it in 2nd and granny’d it home, sometimes riding on the side of the road.

 

[Jim]

Cars with no clutch are easy if they're old school and don't have the stupid clutch/starter lockout (I disable every one I get)- most all of 'em will crank and start in low gear at a stop light- haven't figured out how to kick the ol' TX into starting from a red light 3 vehicles deep. Once I'm rolling it's no issue.

I've broke the clutch cable on a XS and got home exactly that way. Either slip into neutral coming to a stop or just go to 1st and hit the kill switch. Light turns green, lean forward like you're trying to push the bike (still in 1st) and hit the starter button. Bike will chug for a moment then go off on it's merry way.

Easy peasy...

 

[Pat D]

I've broke the clutch cable on a XS and got home exactly that way. Either slip into neutral coming to a stop or just go to 1st and hit the kill switch. Light turns green, lean forward like you're trying to push the bike (still in 1st) and hit the starter button. Bike will chug for a moment then go off on it's merry way.

Easy peasy...

Until everyone stops again for no reason! Remember, I'm east coast, mid-Atlantic, full blown suburban Hell. Population in my county has probably tripled since I was in college. Yeah, I know it can be done, but it's honestly just too easy to call up an Uber to take me home so I can grab the trailer. There's places where there was a stop sign 40 years ago where you now sit through 3 traffic light cycles just to get down the road.

 

[Jim]

Until everyone stops again for no reason! Remember, I'm east coast, mid-Atlantic, full blown suburban Hell. Population in my county has probably tripled since I was in college. Yeah, I know it can be done, but it's honestly just too easy to call up an Uber to take me home so I can grab the trailer. There's places where there was a stop sign 40 years ago where you now sit through 3 traffic light cycles just to get down the road.

I feel your pain... Lived in KC for 30 yrs now. Where we live was almost rural when we moved in. Now, every direction I leave my from house from involves stop lights. It really does suck.

 

[gggGary]

The Ulysses shook loose a shifter bolt 25 miles from home a couple months ago. I was able to ride it home in high gear with little drama. But yeah picked the "least stops" route here and cheated a few stop signs between. clutch took a bit of abuse but the high torque motor made it pretty easy.
Replaced that bolt, then last week a DIFFERENT bolt fell out of the shifter. This time an ace hardware was a block up the road and a replacement bolt was found. Allison and I continued on. Good thing a Buell doesn't vibrate...

 

[grouchie77]

I broke a clutch cable once. Luckily I had a farmer friend who had a trailer that lived nearby. Probably coulda limped it home but I didn't want to give Ole Smokey a reason to pull me over since I didn't have my Class M yet.

Ordered 2 Motion Pros, one to replace the broken one and one to toss in the ammocan saddlebags for the unlikely event my bad luck repeats itself.