LC4 Clutch Cable Problem Finally Bites

Discussion in 'Thumpers' started by markjenn, Jun 19, 2005.

  1. markjenn

    markjenn Long timer

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    Well, after 14K miles without problems, I thought I was immune to the LC4 premature clutch cable breakage problem. No such luck - with nothing but 60 miles of heavy traffic between me and home, mine snapped a few inches downstream of the handlebar adjuster. I made it home without a clutch, but it required some creative paths through traffic that would have caught the attention of Johnny Law if he had been around. And it probably doesn't do the tranny any good to be banging gears like this, especially when trying to get started from a stop. (On longer trips, I carry a spare, but since it was a local ride, I didn't have my full toolkit with me.)

    I may do the trick of routing an extra next to the one in use to make it easier to change out. In any event, if you're driving a LC4, carrying an extra clutch cable is probably a good precaution.

    - Mark
    #1
  2. Nom de Guerre

    Nom de Guerre Long timer

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    A lot of guys route the spare clutch cable along next to the working one. This way, when your cable breaks, you don't have to take a bunch of stuff off the bike to get to the cable routing. I haven't done this yet, but I know I'm going to regret not doing it someday, so it is on my list of things to do next time I have the tank and seat off for other work. Make sure that you seal the ends of the spare with some finger cots and some electrical tape, or a similar solution.
    #2
  3. Arch

    Arch Incurable Gearhead

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    I used to carry a spare and even had to use it once, but no longer. Instead I converted it with Magura's hydro clutch kit, and things have been fine ever since. Nice feel, easy pull. Long as it's down, you might wanna consider it, Mark.
    #3
  4. dezracer

    dezracer Been here awhile

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    You call 14K premature???I dont ,but anyway..why not just upgrade to a terrycable or other name brand that is much thicker more reliable. Thats what I did and its worked for me.
    #4
  5. GT-STMC

    GT-STMC Been here awhile

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    I thought the same. I only got 3,500 out of my first cable. Changed the second at 6,500 because I was going on a trip. Now have 12K and am waiting anyday for the cable to break.
    #5
  6. Nom de Guerre

    Nom de Guerre Long timer

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    This requires some cutting away of the plastic controls assembly housing though, doesn't it? That's been my only hesitation to converting over. I'd hate to botch that up and make a mess of it cosmetically.
    #6
  7. Arch

    Arch Incurable Gearhead

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    Yep, older ones need trimming. I think at some point they changed over to the switchgear that doesn't, like the Duke's. I converted my '01 and had to clearance the switchgear. It was no big deal and pics/info can be found here.

    Anyway, just an alternative to consider. I love my Magura hydro clutches (LC4 & RFS), but certainly a heavy duty cable (with a spare cable zip tied alongside) does the trick nicely. :D
    #7
  8. markjenn

    markjenn Long timer

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    Yes, I agree that 14K is not doing too bad, although I still consider that somewhat premature. I've had bikes go 50K on a clutch cable.

    Thanks for the suggestions on the juice clutch, but after the seat upgrade, the main bearing upgrade, the 2nd radiator fan upgrade, the center-stand tang upgrade, the exhaust upgrade, and the handelbar upgrade, I'm all upgraded out. I'm beginning to think I've got a too-expensive house in a cheap neighborhood.

    I am interested in better clutch cables IF THEY FIT. Some think the Motion Pro Terminator cables are more durable, but there are reports they don't fit properly at the engine side.

    - Mark
    #8
  9. Arch

    Arch Incurable Gearhead

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    :thumb
    #9
  10. Barry

    Barry Just Beastly

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    Magura convert here... I have a 2001.

    The Magura install was easier than the replacement cable I installed, only to go back and then upgrade to the hydraulic unit. The modifying of the switch assembly is both minimal and easy. Simply use a small file and / or emery board (read: nail file).

    YMMV,
    Barry
    #10
  11. creeper

    creeper Still alive...

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    What Arch said... a little Dremel or file work is all it takes. Ride on up... I'll slap one on for ye'. :wink:
    #11
  12. Drif10

    Drif10 Accredited Jackass

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    Went thru 3 in a year. Had mine setup like I used to race: ziptie a new one with the current for when it breaks. Went to a Jack, no more issues that way, except I broke the landing off the actuator end at the lever pull into the case. Wore out. All they are is spoke nipples from euro bicycle spokes, trimmed a little. Carry spares of that, now. Cheaper and easier in the long run.
    #12
  13. Jan from Finland

    Jan from Finland Been here awhile

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    The Magura conversion required quite a lot of cutting in my 2000, but it was easy to do with a soldering iron and file. Now the housing looks crude and I am a bit worried about possible water damage with time. Anyhow, I think it was worth of it. Clutch pull is so much easier now.

    KTM had some trouble with a subcontractor some years ago. I went through three clutch cables in about 5000 km. They corrected the problem with a cable which has a plastic knot at the lever end. The previous one was made of metal. I think that 14k is not too bad even with the new one, because a cable will stick in that time and becomes too hard to pull.
    #13
  14. racer

    racer Long timer

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    Then I upgraded to a KLR. :wink:
    #14
  15. creeper

    creeper Still alive...

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    A new oxymoron. Oh, and the sentence has one in it too. :evil
    #15
  16. lvdukerider

    lvdukerider Las Vegas Nevada

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    526
    I installed a Magura unit on my 00 Duke II over a year ago and I am quite happy with it. The only thing you have to do is file a very slight groove in the switch housing so the little red lever ajustor knob has enough clearance. I have also read of some people fileing down or removing the knob insted of modifying the switch housing.
    #16
  17. Pir8te

    Pir8te over forty victim of fate

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    what is the cost and do yo have a part #
    #17
  18. Rad

    Rad Done riding

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    I had one pre-routed in place and I had heat shrink wrapped both ends with some large ones made for elec connections. Kept it in great shape......Then I saw Arch's thread and went hydro :thumb
    #18
  19. Nom de Guerre

    Nom de Guerre Long timer

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    Well, one of these days I might just do that... ride on up for a visit that is. I imagine I can probably handle the dremel work if I switch over to the Magura. I'm sure it's just a matter of time. New Wings Ti exhaust first. :nod
    #19
  20. creeper

    creeper Still alive...

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    The Parts Unlimited number is M0120490, retail is $249. Shop around you might save $30 - $40.

    Install instructions.
    #20