R1100 Gs clutch cables being eaten...

[gooffer]

Well 5 cables in less then 20k now at 61100 I just broke the 5th one since about 40 mark....

So I replaced the lever, nothing seems to bind, there isn't any slop, the amount of pressure seems normal...

been reading about this, where is the felt bit located ? not sure I see that anywhere... I am ordering 2 more and going to use tractor grease to lub the end up like there is no tomorrow. but basicly I am going to unload this bike it's not fun to ride and keep getting to ride back home without a working clutch...

is the R1150 Gs design any better ?

I have bought 3 used cables, 2 new once, one new lever nothing seems to fix this design flaw

[Tosh Togo]

Originally Posted by gooffer

Well 5 cables in less then 20k now at 61100 I just broke the 5th one since about 40 mark....

So I replaced the lever, nothing seems to bind, there isn't any slop, the amount of pressure seems normal...

been reading about this, where is the felt bit located ? not sure I see that anywhere... I am ordering 2 more and going to use tractor grease to lub the end up like there is no tomorrow. but basicly I am going to unload this bike it's not fun to ride and keep getting to ride back home without a working clutch...

is the R1150 Gs design any better ?

I have bought 3 used cables, 2 new once, one new lever nothing seems to fix this design flaw

Are the cables breaking in the same location?... if so, where?...

[JimVonBaden]

You are not actually lubing the cable, right? Where is it breaking?

Jim

[gooffer]

tip in the handle rips off and frazzels I know when it's about to go as the clutch keeps coming sooner and sooner when then suddenly it doesn't come out of gear, adjusting the clutch gives me another 2 gear chances before the end rips off...

[JimVonBaden]

Sounds like your handle has a burr or defect. Time to replace it. That cable usually lasts 50K miles or more, lots more!

No sense throwing out a bike for a simple issue.

Jim

[gooffer]

I just bought a new handle... still same problem

[JimVonBaden]

Something is binding. If it is not the handle, then it might be the alignment between the handle and the mount.

Jim

[MSteven]

Check to see if the pivot screw/ lever/ mount are worn allowing the lever to droop. This will cause a misalignment of the cable slot in the lever and the slot in the mount to be misaligned.
This puts a very large amount of strain to the cable right at the point where the cable end is. I busted two clutch cables on my old BMW, and that was the problem. I fixed it by replacing the nylon bushing that is on the pivot screw/bolt. That and I opened up the ends of the cable slot so the cable won't get hung up on the adge. This may not be what you have going, but it would be worth looking into.
Mark

[vintagerider]

Originally Posted by MSteven

Check to see if the pivot screw/ lever/ mount are worn allowing the lever to droop. This will cause a misalignment of the cable slot in the lever and the slot in the mount to be misaligned.
This puts a very large amount of strain to the cable right at the point where the cable end is. I busted two clutch cables on my old BMW, and that was the problem. I fixed it by replacing the nylon bushing that is on the pivot screw/bolt. That and I opened up the ends of the cable slot so the cable won't get hung up on the adge. This may not be what you have going, but it would be worth looking into.
Mark

File the slot in the barrel. If the problem continues then you may have to replace the clutch push rod and or the bearing in the rear control lever. Goood to have practice on how to change that rear lever anyhow. The trick for me was to install the bolt to the gear box w/o the lever and note the angle and clearances.

[gooffer]

yes I wonder if the piece that the cable slips into in the handle actually rotates when I actuate the clutch but since there is no way to see anything while operating it I must assume it doesn't. I figured new handle would do it, it didn't so now I am thinking it must be the bit inside that gets hung up in one position and doesn't rotate a little bit as the lever moves.... some other posts talked about a bit of felt that's inside somewhere I have no seen it, would anyone know if it could be part of the adjustment part of the clutch ?...

[UncleMark]

Lube the barrel that the end of the cable goes into. If it doesn't turn freely in the lever, it can wear out quickly. I had to replace twice in the first year, but not since I lubed it.

[fivetimeson129]

goofer, is it perhaps time to take the bike to a pro

[gooffer]

going to try the lube bit, cannot be something that difficult. driving around the world with this bike is not something I would consider how many clutch cables could one take along ? I changed on in the tribal areas of western pakistan using a throttle cable of a moped worked longer then the OEM original... yes Pro mechanics are all fine and good 2h+ to max plus 2h back I don't have that kind of time.

[mark883]

Something is absolutely not right.

FYI, the clutch cable will work exactly the same on the center stand as it does going down the road at 20, 40 or 80 mph.

How stiff is the clutch? How many miles on the bike? Since a spline lube?

There should always be a nickle thickness worth of slop in the clutch handle action, before you feel the clutch engage.

The 1100gs cable is better than the 1150/1200 hydraulic. You can replace a cable on the side of the road, anywhere in the world. A cable could be McGuyvered anywhere in the world. You can't replace the 1150 cylinder without tearing the ass end of bike apart.

Yes, this is the bike people take around the world. With a spare final drive big bearing & seal in the bags, and an extra clutch cable ziptied along the in-service cable, just in case.

[Anorak]

The felt piece is #7 in this illustration, link. It fits in the adjuster. If it's damaged or missing, the cable will break quickly.