Clutch cable woes

More
12 Oct 2005 20:11 #1214 by R Dresden
Clutch cable woes was created by R Dresden
Hey all. I have had a terrible time over the years keeping clutch cables in one piece on my KZ1000a. It is not uncommon to break at least one ayear if not more. Now I never claimed to be an ace mechanic but after installing the cable I've taken the bike to my local dealership and they say they are installed just like they should be. But, sooner than later, it will break right where the cable routes through the clutch lever. Right at the "ball" that fits into the handle itself.

Any suggestions? It's not much fun trying get a horse like that home riding through town with no clutch! LOL

Peace,
Rodger B)

Post edited by: R Dresden, at: 2005/10/12 23:11

Please Log in or Create an account to join the conversation.

More
12 Oct 2005 20:17 #1220 by savedrider
Replied by savedrider on topic Clutch cable woes
Are you lubing it often enough?

Get right or get left! <*{{{><

Please Log in or Create an account to join the conversation.

More
12 Oct 2005 20:19 #1221 by R Dresden
Replied by R Dresden on topic Clutch cable woes
You know it....as often as possible. It pulls silky smooth and then SNAP...I'm off to the dealership or calling the catalog company again.

Post edited by: R Dresden, at: 2005/10/12 23:20

Please Log in or Create an account to join the conversation.

More
12 Oct 2005 20:25 #1222 by apeman
Replied by apeman on topic Clutch cable woes
On my KZ750H I had a similar problem, breaking a cable one month, then noticing I was down to a few cable strands only a few months later. I replaced that one with a cable which looked to be of much better quality (teflon lined, beefy looking sheathing, good solid end pieces). It has been working fine now for two years. I do not know the name brand, but I learned a lesson about getting the cheapest cable on eBay. For an extra five or eight bucks, go for a better quality.

Also, lube it with heavy weight oil or lithium grease, not with WD40.

Petaluma and Truckee, CA -- member since Jan. 23, 2003;
PREVIOUS KZs: 1980 KZ750H with 108,000 miles; 1980 KZ750E with 28,000 miles; and KZ750H street/cafe project, all sold a few years back.

This is what I do for fun, not for work. It is art, with a little engineering thrown in.

Please Log in or Create an account to join the conversation.

More
13 Oct 2005 13:28 #1426 by Old-Skul
Replied by Old-Skul on topic Clutch cable woes
The shorter bars on my KZ650 caused the cable to bend tightly and I went through a clutch cable from Parts Unlimited every 3 months. Then I bought a stock cable from Kawasaki at 3 times the price. It's lasted for over a year. I keep a cheap one on the shelf for a spare if I need it, but I will continue to order the stock parts from now on when it comes to cables.

In this case the stock part is worth the extra cost. Goto www.bikebandit.com for a good deal on the stock part.

Please Log in or Create an account to join the conversation.

  • KZQ
  • Offline
  • Administrator
  • Walking Behind the Corn May Not Be All That!
More
13 Oct 2005 14:21 #1437 by KZQ
Replied by KZQ on topic Clutch cable woes
Hey Dresden,
Watch the barrel end of the clutch cable as you pull it. Is the barrel turning so that the cable pulls straight or is the barrel bound up and causing the cable to bend every time?

Just a thought
KZCSI

www.KZ1300.com
Riders:
1968 BSA 441 Shooting Star, 1970 BSA 650 Lightning, 1974 W3, 1976 KZ900, 1979 KZ750 Twin, 1979 KZ750 Twin Trike, 1981 KZ1300, 1982 KZ1100 Spectre, 2000 Valkyrie, 2009 Yamaha Roadliner S. 1983 GL 1100
Projects:
1985 ZN1300

Please Log in or Create an account to join the conversation.

More
13 Oct 2005 14:23 #1439 by Jeff.Saunders
Replied by Jeff.Saunders on topic Clutch cable woes
I would say the combination of poor routing and being close to an exhaust header causes most of the failures. Additionally, some of the handlebar mounts (perches) get tweaked with the bike falling over and the cable doesn't get a straight path and scrapes on the mount.

Also make sure the mechanism behind the sprocket cover is greased and free moving, and the clutch pushrod isn't grooved and catching somewhere. One trick with the pushrods - on many engines you can clean them up and put them back the other way around to move the worn area to where it doesn't matter.

This email address is being protected from spambots. You need JavaScript enabled to view it.
www.z1enterprises.com

Z1 Ent on Facebook,

Please Log in or Create an account to join the conversation.

More
13 Oct 2005 19:07 #1519 by Z1R rider
Replied by Z1R rider on topic Clutch cable woes
could be the lever it's self that's worn egg shaped where the cable lug rides, makes the cable twist a little with every pull, just a thought

ps: I've had the same cable for 24 years now

Post edited by: z1r rider, at: 2005/10/13 22:10

1978 KZ1000, Z1R
1999 250 Ninja race bike
2013 WR250F, fun in the dirt

Please Log in or Create an account to join the conversation.

  • Biquetoast
  • Offline
  • User
  • King Jeremy The Wicked
More
13 Oct 2005 19:31 #1528 by Biquetoast
Replied by Biquetoast on topic Clutch cable woes
R Dresden wrote:

...But, sooner than later, it will break right where the cable routes through the clutch lever. Right at the "ball" that fits into the handle itself.

Any suggestions? ...


Geez, what brand are you using? ;)

That is strange. Does the cable break from strands breaking, or does the ball become un-soldered?

(1.) '75/'76 KZ400D - Commuter
(2.) '78 KZ750B3 Twin - Commuter
(3.) '78 KZ750B3 Twin - Commuter
(4.) '75 KZ400D - Sold
kz750twins.com

Please Log in or Create an account to join the conversation.

More
13 Oct 2005 19:39 #1536 by Z1R rider
Replied by Z1R rider on topic Clutch cable woes
:laugh: it's a stock Kaw piece, had to replace the original about a year after I got the bike, it was totaled when I got it and the cable had a nasty kink in it, the dirt bikes that we've had always seem to break the cables right next to the ball at the lever, after we put new levers on them we didn't break many cables

1978 KZ1000, Z1R
1999 250 Ninja race bike
2013 WR250F, fun in the dirt

Please Log in or Create an account to join the conversation.

More
13 Oct 2005 23:34 #1602 by R Dresden
Replied by R Dresden on topic Clutch cable woes
If I remeber right, they (cables) came from either Dennis Kirk or Parts Unlimited. The cable itself frays and snaps a little at a time. It has new levers on it so I know the ball isn't egg shaped or otherwise defective. It does route fairly close to the exhaust though. I run the 4 separate drag pipes for the exhaust and try to keep it as far away as possble. I would like to find either a steel braided cable or a kit that I could do it myself. Has anyone seen anything along those lines?

Thanks for the info guys. I really appreciate it!

Peace,
Rodger B)

Please Log in or Create an account to join the conversation.

More
14 Oct 2005 12:16 #1732 by Old-Skul
Replied by Old-Skul on topic Clutch cable woes
The cables I ordered were also from Dennis Kirk (who apparently sourced them from Parts Unlimited).

Try ordering the stock Kawi piece it is much better. Again, the DK ones lasted 3 months on my bike, the stock kawi one hasn't broken yet. The DK ones are crap in my humble opinion.

Please Log in or Create an account to join the conversation.

Powered by Kunena Forum