Clutch Cable Problem

Hey everyone, I have an '81 Maxim 650. This is a very unusual problem, and I'm having trouble identifying why this is happening. So far I've gone through three clutch cables. The first one was the original cable from factory that went last year in September, which had over 80k kms on it.. I replaced it with a brand new one and rode til the end of the season last year and then the whole season this year. I totalled nearly 19k kms on it, and this one snapped. Right at the handle. Which was the case in the first snap. And now, just recently, I had a used one from a bike with much lower km on it than mine (Mine rolled over 100k and is now at 700km), and this one snapped in the exact same fashion.

Now I must mention two things. One, my clutch slips and is increasingly slipperier. This is part of my suspicion. Second, I adjusted the arm on the clutch to free up a little tension since it was so taught. What I'm having dificulty understanding is why this is happening in this fashion? All the cables were the correct size and in the correct position and routing.

Could it be that my clutch needs replacing so badly that it's just eating my cables?

This only happens when I pull in the clutch and am about to stop anyway, putting it into 1st. I also notice that off and on its a real wrestle to get it into neutral from first. And when I go into 1st from neutral is slams and rocks the bike all at the same time. Before, I've tried slacking it off, but it just creates the roll and doesn't disengage the clutch fully.

I know, this is a lot to read, but it's such a weird problem it takes alot to explain. It's getting on my nerves how many times this has happened recently.

Thanks in advance!

 

The shifting issue is usually adjustment like you suspect. Also I'm not a clutch expert but my understanding is that if you replace the clutch early enough you can just replace the friction plates, but if you let is slip it can ruin the other plates (not sure of the term) so you should take care of that ASAP.

Here is a shot at your breakage - have you carefully inspected the clutch handle? I wonder if there is a burr or something that is wearing the cable until it breaks.

 

Yeah that indeed is a strange problem.
I'd definitely check for a burr or raw metal rubbing, as bill said.
Is this slipping and hard shifting happening all the time, or have you noticed it happens mainly just prior to your cable snapping into two pieces?

 

Thanks guys! I was talking to a guy at my local sport and lawn dealer and he suggested I check for a burr on the handle as well. It makes sense at least.

But I know I have to replace the clutch, it's getting terrible. The slipping and hard engaging is all the time.


It slips in top gear if I roll on. Probably the original clutch in it and it has over 100,700 km.