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General Category >> Rubber Side Down! >> clutch cable broke
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Message started by 01suzsavage on 07/03/15 at 17:47:59

Title: clutch cable broke
Post by 01suzsavage on 07/03/15 at 17:47:59

So just went out of town tonite for 4th july weekend. 250 miles from home clutch cable snapped. Had to ride last 50 miles without it. I was able to get some bulk cable and ends to crimp on im gonna try to make one. There isnt a dealership in michigan that stocks the cable (called all of them pretty much). Any suggestions or anybody around lansing have a spare cable? 2001 ls650. Thanks

Title: Re: clutch cable broke
Post by Kris01 on 07/03/15 at 18:20:49

Sorry for your trouble! How did you shift into 1st from a stop?

Title: Re: clutch cable broke
Post by chzeckmate on 07/03/15 at 18:29:12

5A6378622120110 wrote:

Sorry for your trouble! How did you shift into 1st from a stop?

You've got to do the Fred Flintstone shuffle while in neutral and then pop it into first...then you can use the clutchless shifting technique to move through the rest of the gears.

Title: Re: clutch cable broke
Post by Kris01 on 07/03/15 at 18:44:23

But wouldn't you have to paddle pretty quickly across a busy intersection and hope your big single doesn't die (from compression braking)? I tried push starting my bike once and it absolutely refused!

Title: Re: clutch cable broke
Post by verslagen1 on 07/03/15 at 19:16:36

don't fear the reaper... remember your clutch cable is broke?
squeeze the clutch lever it'll allow to push the starter button and run like mad for an assisted start.
and if you think it'll help... yell "YABBA DABBA DOOOOO!!!"

Title: Re: clutch cable broke
Post by Kris01 on 07/03/15 at 19:28:05

415245445B5650525906370 wrote:

Bad mental image Versy! ;D

Title: Re: clutch cable broke
Post by 01suzsavage on 07/03/15 at 19:33:29

I fortunately only had to do 2 flintstone shuffles after it broke lol. I was able to avoid red lights most of the way. But ya u can roll, put it in first (bucks like a bronco), than shift like normal without using a clutch after that. Actually shifted pretty smooth. Can't even find cable online other than ebay. This sucks

Title: Re: clutch cable broke
Post by Boogie_with_Stu on 07/03/15 at 19:57:03

Cant find a cable online? Hmm..
http://www.2wheelpros.com/oem-parts/suzuki-cable-assy-clutch-58200-24b12-part.html?gclid=CjwKEAjw5disBRCA5r7OjsK_-UgSJAC27JPgOzrV6tK_Zm7ogzWPeEiwW5iVSQA25dMHaNz-RTsKvxoCp8Dw_wcB

http://www.jcwhitney.com/motion-pro-clutch-cable/p3075192.jcwx

http://www.suzukipart.com/oemparts/a/suz/50d32faef8700232d0b3d905/handlebar

that was just a 2 min peek.

I have one I got off ebay as a spare. If you get jammed up, shoot me a PM . I'll get it to you for $12 shipped.

Title: Re: clutch cable broke
Post by Dave on 07/04/15 at 03:04:22

5D464C4A5D4E4C4A5D1F1E1E1C2F0 wrote:

Can't even find cable online other than ebay. This sucks

You have to remember that Savage is a low production motorcycle. There is very little aftermarket stuff available for it......and most people (even the dealer) don't have parts in stock for this bike. While the oil filter and a few other parts might fit other bikes and be available in stock.....most likely the only place you can get parts like cables will be your local or online Suzuki Dealer. And most likely the local and online dealers will list the part - but will not have it in stock and they all will have to order it from the Suzuki warehouse.

Title: Re: clutch cable broke
Post by Art Webb on 07/04/15 at 08:04:20

Good Idea to get TWO (they're not that expensive) and zip tie the spare to the one in use
one in use breaks, pop it loose and put the ends of the spare in place
Off you go
Also. some folks on the XS forum have had trouble with motion pro cables (mine is fine) so there's that to consider

Title: Re: clutch cable broke
Post by Dave on 07/04/15 at 11:44:24

I would try and figure out why the first one broke. They normally don't break.....so you either had one where the lever end was not lubed properly and the end was not rotating in the lever - or it was catching on something and it wore through the cable.

Title: Re: clutch cable broke
Post by 01suzsavage on 07/05/15 at 01:16:31

Got the bike home safe. 240 miles with my homemade clutch cable today[ch9996]. Ordered a new suzuki cable should be here in a few days

Title: Re: clutch cable broke
Post by chzeckmate on 07/05/15 at 07:18:54

Cheers! I'll bet Wilma, Pebbles, and Dino gave you a warm welcome home ;D

Seriously though, for anyone caught in that situation going forward, would you mind telling us where you got the bulk cable and ends and how you used them to make the homemade remedy?

Title: Re: clutch cable broke
Post by 01suzsavage on 07/05/15 at 07:33:26

My bro in law is a fleet mechanic for a farm. He had the cable and a kit with different size aluminum ends that crimp on. Its supposed to be to replace broken throttle cables. I ran it through the existing cable sheath and looped it around at each end. Pulled it tight, put crimps on, and adjusted the clutch. Worked great!

Title: Re: clutch cable broke
Post by 01suzsavage on 07/05/15 at 07:34:59

I think he said they have rolls of the bulk cable at tractor supply or the hardware store

Title: Re: clutch cable broke
Post by chzeckmate on 07/05/15 at 08:06:59

I figured you were going to say lawn mower throttle cable from the hardware store. That would be the first thing I'd try if I had no other options. Good work!...Glad you made it home safe and sound.

Title: Re: clutch cable broke
Post by justin_o_guy2 on 07/05/15 at 08:25:57

Other stuff suddenly starts looking useable in a bind. Throttle return spring broke on a Mack truck, out in the boonies of West Texas,, except for this burger/beer joint, Miniskirt Junction, I bought the spring off of the screen door, used wire from a fence, got it home. Three dollars..

Title: Re: clutch cable broke
Post by Boogie_with_Stu on 07/06/15 at 13:06:50

4D5254534E4978487840525E15270 wrote:

MacGyver lives!!

I love stories like this. That has been the way I do things all my life....so much so that my last job (was there 15 yrs) I was THE go to guy when engineering or maintenance couldnt figure out a solution.

Most of the presses, molding machines and riveters in our plant were well over 40 yrs old. We had some screw machines that had "War Department" on the boiler plate labels :o