Worn clutch cable

2948 Views 29 Replies 10 Participants Last post by Gianfranco75, 3 mo ago

Gianfranco75

Discussion Starter · 4 mo ago

Hi everyone, have you noticed that when the clutch cable is operated, it scrapes on the end of the iron sheath, wearing out? The defect was present on my previous 650 L4, and is present again on the current 650 xt 2021...I clean and grease that point regularly, but that's not enough, the thread tends to wear out and then needs to be replaced before breaking, leaving you to feet. The cable makes a very tight curve passing over the motor mount and there is no way to intervene. Some motorcycles have the end of the sheath threaded and locked with a nut on the end bracket, so that when it is in action and pulled it remains perfectly still, so that the wire works in the center of the sheath. Check it out for yourself and if you find a solution, post it.

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richlandrick

· #2 · 4 mo ago

@Gianfranco75

Got pics?

Rolex

· #3 · 4 mo ago

My mates Wee had the same problem but it was caused by his aftermarket lever.

Going back to the OME lever fixed it.

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Gianfranco75

Discussion Starter · #4 · 4 mo ago

photos.app.goo.gl

New item by Gianfranco Marraffa

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photos.app.goo.gl

New item by Gianfranco Marraffa

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From the photos it is clear that the cable does not work perfectly in the center of the sheath, rubbing always and only in the upper part of the wire. Over time it wears out and breaks down. For me it's a design flaw.

richlandrick

· #5 · 4 mo ago (Edited)

I'm glad you posted pics. I was thinking of the other end of that cable.

I think you are correct. If that lower clutch cable guide held the last inch or so of the cable straight at the end the wear on the metal casing at the end of the cable would be eliminated.

I'm sure a simple fix could be fabricated one way or another.

Let me know if you find that cable guide on a parts diagram. I looked, but couldn't find it.

Reactions: 1

STCorndog

· #6 · 4 mo ago

I might try something different. Remove the lower cable mount from the bike and clamp it in a vise. Bend (rotate) the barrel section of the mount to correctly align the cable with the direction of pull.

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Gianfranco75

Discussion Starter · #7 · 4 mo ago

The strange thing is that only I have noticed this problem, the first time I had to change the clutch cable at 60,000km on the previous 650, now with the new 650 xt I'm at 32,000km and I noticed that the upper part has already filed some thread! I've already ordered the new one. Can you confirm that this defect is also present on your bikes? just touch the thread at the final exit of the pawl and understand if it is worn out, it will be rough to the touch..

blaustrom

· #8 · 4 mo ago (Edited)

1+ on ST's suggestion. Just bend the barrel of the holder enough so that the cable comes out straight. Its not a design fault, its just a really cheap and primitive part!

1st Gen Setup:

2017 setup is on the right side of the engine, completely different than 1st gen Wee:

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STCorndog

· #9 · 3 mo ago

I have a hydraulic clutch @Gianfranco75 .

Reactions: 1

nvr2old

· #10 · 3 mo ago

My 06 650 went 122K miles and never any problem(Checked several times). Don"t even know anyone that did.

Reactions: 1

richlandrick

· #11 · 3 mo ago

STCorndog said:
I might try something different. Remove the lower cable mount from the bike and clamp it in a vise. Bend (rotate) the barrel section of the mount to correctly align the cable with the direction of pull.

That would work if the cable mount was not already in line with the direction of the pull. If that is the case shame on Suzuki.

V-Tom

· #12 · 3 mo ago

STCorndog said:
I have a hydraulic clutch @Gianfranco75 .

Vertebrate Cartoon Happy Mammal Gesture

..Tom

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blaustrom

· #13 · 3 mo ago

nvr2old said:
My 06 650 went 122K miles and never any problem(Checked several times). Don"t even know anyone that did.

The newer models have a different clutch setup than the 1st gen WEE. That's why you have no issues.

V-Tom

· #14 · 3 mo ago

nvr2old said:
My 06 650 went 122K miles and never any problem(Checked several times). Don"t even know anyone that did.

I don't think my 2006 DL650 ever needed a new clutch cable in 202,435 km / 125,787 miles.(but I did have a minor issue with the worm gear mechanism.) My 2012 DL650 only had an issue at 99,475 km / 61,811 miles. The lever side wore at the cable end where cylindrical end rotates in the lever. I tracked that back to the user (me!) not lubing the part so it binded and flexed the cable until it was about to break.(I noticed it with one or two strands of cable left.)

..Tom

nvr2old

· #15 · 3 mo ago

blaustrom said:
The newer models have a different clutch setup than the 1st gen WEE. That's why you have no issues.

Thanks. Never worked on a 12-16 model and only 1 2017.

Gianfranco75

Discussion Starter · #16 · 3 mo ago

Someone, searching the net, talks about adjusting the slack between 10 and 15 mm, and so far there are, but they also say that the line with the coupling arm must have an angle between 90 and 80 degrees. Does anyone know how to get this angle? perhaps it serves to perfectly center the wire in the center of the sheath and make it work without wearing out. Although on my bike I think it already has a 90 degree angle and you can see that in the pics I posted. I also noticed that when at rest the thread is almost in the centre, but if I pull the lever it is clear that when the thread is under tension it rises and touches the upper part. I'm trying to figure out if this is the case on all 650s from 2017 onwards, or if it's a problem only on my bike. If you check on your bikes, do me a favor! If you can also put some photos of the affected area like I did. Thank you.

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Gianfranco75

Discussion Starter · #17 · 3 mo ago

Arrived changed the clutch cable, 2 hours to do everything right. I've tried everything but there's no way to get the wire to work in the center of the sheath. Let's see how long the new cable lasts! damn suzuki and whoever designed this system.

photos.app.goo.gl

4 new items by Gianfranco Marraffa

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Brockie

· #18 · 3 mo ago

It seems to me that the issue is that the cable is curved upwards as it enters the end connector. I wonder if a hook type bracket, using the circled mounting bolt, could be manufactured in a way to give downward pressure on the top of the cable sheath before where the cable enters the existing holder.
That would then align the cable before it enters its holder keeping it straight, and not curved, which might stop the interior cable from rubbing against its sheath.

Air gun Automotive design Shotgun Trigger Auto part

I found this image to give you an idea of what I was thinking. The cable needs to be straightened.

Door Handle Household hardware Door handle Rectangle

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V-Tom

· #19 · 3 mo ago

Gianfranco75 said:
Arrived changed the clutch cable, 2 hours to do everything right. I've tried everything but there's no way to get the wire to work in the center of the sheath. Let's see how long the new cable lasts! damn suzuki and whoever designed this system.

4 new items by Gianfranco Marraffa

photos.app.goo.gl

Have you looked at other bikes of the same year and model to see if yours is the same? I don't recall hearing issues at this end of the clutch cables and my (very poor) memory thinks the cable exited more straight than your photo shows.

..Tom

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Gianfranco75

Discussion Starter · #20 · 3 mo ago

V-Tom said:
Have you looked at other bikes of the same year and model to see if yours is the same? I don't recall hearing issues at this end of the clutch cables and my (very poor) memory thinks the cable exited more straight than your photo shows.

..Tom

It was the same on my previous 650 2014, in fact they mount the same clutch cable and bracket, and I had to change the clutch cable there too, even if after doubling the kilometers at around 60,000. On this bike instead I changed the cable at 32500 kms. I asked other owners of my same 650 xt 2021 model to check if this problem is also present on their bikes, but I have not had any answers. It would be nice to have photos of other bikes and compare them with mine, I need to understand if it's a problem with my bike, and it would already be the second bike with the same problem... or is it common to all the same models. Check and write here thanks.

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