Clutch handle went limp!

BoKing · March 16th, 2015, 12:23 AM

Just left from my girlfriend's house. Operating the bike normally, When I pulled on the clutch handle I felt resistance then a small snap. I pull it again (normal strength, didn't force anything) and felt the same resistance, the same snap, then it went limp. When I pull the handlebar it now has zero resistance, and just sits there floppy, and of course has no interaction with the clutch cable.

Parked the bike on a residential side street for the night as I can't really examine anything in the dark.

Going back tomorrow to look at it. What I did notice (this may or may not be normal) was that, this is kind of hard to describe, the junction where the cable goes into the handlebar looks like it was pulled out an inch or so. I wish I could describe this better, but a circular metal piece that has ridges on it like it was intended to be twisted/turned looks like it should be flush with the contraption/handlebar but is elevated out an inch or so.

Hope that made sense.

I'm just asking here to check what I should be expecting or looking for when I go assess it tomorrow. Hopefully it's an inexpensive fix.

As always, I appreciate your expertise here. Thanks!

Ghostt · March 16th, 2015, 12:49 AM

Was the clutch still operating? If not sounds like a clutch cable failure/broke. Those small snaps, were the strands of metal that make up the cable, hope your local bike shop has one in stock.

Do you lube your cables? If not I personally use this
Bike Aid Dri-Slide 4oz. Lube with Needle Nozzle https://www.amazon.com/dp/B001F2Y25G..._1VObvb1VCNDV9

Flying · March 16th, 2015, 12:53 AM

First find out if your cable has snapped or not. If it is, replace that.

The turning bit is the clutch cable adjuster nut or screw, possibly got de-threaded and broke from wear and tear.

Kawasaki part #s 92009-1134 and 92015-1197. Go to ebay or your local dealership's parts guy.

When this is all over, start lubing your cables regularly so that this doesn't happen again.

BoKing · March 16th, 2015, 01:02 AM

92015 is the part I was referring to. It appears as if it is was sticking up or out like an inch.

So here's the thing, I replaced my clutch cable a little over a year ago. I paid the dealership to do the whole thing, parts and labor. Is it common for clutch cables to go like every 18 months or so?

Flying · March 16th, 2015, 01:09 AM

People have kept their stock cables going for 2+ years with regular maintenance. Do you lubricate them?

BoKing · March 16th, 2015, 01:14 AM

Sorry I forgot to answer that before.

I do not lubricate them. I will after this though, assuming that's what happened. Cables aren't too expensive if I remember!

fishdip · March 16th, 2015, 02:11 AM

We need to get CC Cowboy in this. he is use to dealing with limp stuff.

Flying · March 16th, 2015, 03:30 AM

This seems like a really straightforward replacement job. The price ranges from what's on ebay to how much you are willing to pay for dealership labor and parts markup. I would strongly recommend to go the ebay route.

Here is a control set with no cable:
http://www.ebay.com/itm/07-KAWASAKI-...5cb26b&vxp=mtr

There are plenty of pregen cables running around, take your pick. The whole set would cost around $30-$40.

And get to lubing the cables, there a number of ways:
MotionPro tool: http://www.motionpro.com/motorcycle/...FdcXgQod31IArg
Cheap basically the same tool: http://www.ebay.com/itm/Universal-Mo...-/121142774160
Syringe method: http://www.pet360.com/product/52039/...FXQQ7AodQywAlA
EZ Glide Tool: https://www.youtube.com/watch?v=rF43XTc3io8

ieathonda · March 16th, 2015, 07:29 AM

ive noticed the clutch cable has nylon sheathing, would lubing it still be ok?

Ghostt · March 16th, 2015, 07:40 AM

Quote:

Originally Posted by ieathonda

ive noticed the clutch cable has nylon sheathing, would lubing it still be ok?

Yes, just make sure it's cable lube.

I have personally tried several kinds over the years, I use to use the Motion Pro cable lube,Motion Pro Cable Lube 15-0002 https://www.amazon.com/dp/B00230EAOW..._7TUbvb1MK663A, with the cable lube tool Motion Pro 08-0182 Cable Lubber https://www.amazon.com/dp/B0012TYX9W..._wUUbvb13NSYTR

Then I found this,

Bike Aid Dri-Slide 4oz. Lube with Needle Nozzle https://www.amazon.com/dp/B001F2Y25G..._qPUbvb1MA3974 and now this is my choice, ease of use, and works extremely well.

March 16th, 2015, 12:23 AM	#1
BoKing ninjette.org member Name: Bo Location: Albuquerque New Mexico Join Date: Jan 2013 Motorcycle(s): 2007 Ninja 250 Posts: 22	Clutch handle went limp! Just left from my girlfriend's house. Operating the bike normally, When I pulled on the clutch handle I felt resistance then a small snap. I pull it again (normal strength, didn't force anything) and felt the same resistance, the same snap, then it went limp. When I pull the handlebar it now has zero resistance, and just sits there floppy, and of course has no interaction with the clutch cable. Parked the bike on a residential side street for the night as I can't really examine anything in the dark. Going back tomorrow to look at it. What I did notice (this may or may not be normal) was that, this is kind of hard to describe, the junction where the cable goes into the handlebar looks like it was pulled out an inch or so. I wish I could describe this better, but a circular metal piece that has ridges on it like it was intended to be twisted/turned looks like it should be flush with the contraption/handlebar but is elevated out an inch or so. Hope that made sense. I'm just asking here to check what I should be expecting or looking for when I go assess it tomorrow. Hopefully it's an inexpensive fix. As always, I appreciate your expertise here. Thanks!

March 16th, 2015, 12:49 AM	#2
Ghostt in your machine Name: Scott Location: Summer Shade, Ky. Join Date: Oct 2014 Motorcycle(s): 98 Ninja 250/F12 aka ZX-2R "SERENITY", 91 Ninja 500/A5 aka ZX-5R "Phoenix", 84 Honda GL1200A "SIREN" Posts: A lot. Blog Entries: 25 MOTM - Jun '17, May '16, Mar '15	Was the clutch still operating? If not sounds like a clutch cable failure/broke. Those small snaps, were the strands of metal that make up the cable, hope your local bike shop has one in stock. Do you lube your cables? If not I personally use this Bike Aid Dri-Slide 4oz. Lube with Needle Nozzle https://www.amazon.com/dp/B001F2Y25G..._1VObvb1VCNDV9 __________________________________________________ *violente et ignorantia* ZX-2R BLOG *Twitter and Instagram = Ghostt_Scott* *I'm not here to change your mind, just to inform.*

March 16th, 2015, 02:11 AM	#7
fishdip ninjette.org certified postwhore Name: Fish Location: co Join Date: Apr 2013 Motorcycle(s): 250/300 Posts: A lot.	We need to get CC Cowboy in this. he is use to dealing with limp stuff. __________________________________________________ Hey Unregistered never go faster than your brakes can be applied...

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
WTB: Clutch lever, handle bar end, dummy cap, and clutch lever holder. 09 250r	SwagenGTI	Items Wanted	5	March 4th, 2013 12:20 PM
Shifting lever completely limp	BoKing	1986 - 2007 Ninja 250R Tech Talk	8	January 16th, 2013 11:36 AM
[crash.net - WSBK] - Haslam leaps over pain barrier to limp onto podium	Ninjette Newsbot	Motorcycling News	0	September 8th, 2010 03:50 AM
2005 left handle bar and screw and nut for clutch handle	gogiburn	Items Wanted	4	June 24th, 2010 01:17 AM
Clutch handle play	Cab305	2008 - 2012 Ninja 250R Tech Talk	2	April 22nd, 2010 05:26 PM

March 16th, 2015, 12:53 AM	#3
Flying ninjette.org sage Name: - Location: somewhere cold Join Date: Jun 2013 Motorcycle(s): 2010 Ninja 250 Posts: 596 Blog Entries: 1	First find out if your cable has snapped or not. If it is, replace that. The turning bit is the clutch cable adjuster nut or screw, possibly got de-threaded and broke from wear and tear. Kawasaki part #s 92009-1134 and 92015-1197. Go to ebay or your local dealership's parts guy. When this is all over, start lubing your cables regularly so that this doesn't happen again.

March 16th, 2015, 01:02 AM	#4
BoKing ninjette.org member Name: Bo Location: Albuquerque New Mexico Join Date: Jan 2013 Motorcycle(s): 2007 Ninja 250 Posts: 22	92015 is the part I was referring to. It appears as if it is was sticking up or out like an inch. So here's the thing, I replaced my clutch cable a little over a year ago. I paid the dealership to do the whole thing, parts and labor. Is it common for clutch cables to go like every 18 months or so?

March 16th, 2015, 01:09 AM	#5
Flying ninjette.org sage Name: - Location: somewhere cold Join Date: Jun 2013 Motorcycle(s): 2010 Ninja 250 Posts: 596 Blog Entries: 1	People have kept their stock cables going for 2+ years with regular maintenance. Do you lubricate them?

March 16th, 2015, 01:14 AM	#6
BoKing ninjette.org member Name: Bo Location: Albuquerque New Mexico Join Date: Jan 2013 Motorcycle(s): 2007 Ninja 250 Posts: 22	Sorry I forgot to answer that before. I do not lubricate them. I will after this though, assuming that's what happened. Cables aren't too expensive if I remember!

March 16th, 2015, 03:30 AM	#8
Flying ninjette.org sage Name: - Location: somewhere cold Join Date: Jun 2013 Motorcycle(s): 2010 Ninja 250 Posts: 596 Blog Entries: 1	This seems like a really straightforward replacement job. The price ranges from what's on ebay to how much you are willing to pay for dealership labor and parts markup. I would strongly recommend to go the ebay route. Here is a control set with no cable: http://www.ebay.com/itm/07-KAWASAKI-...5cb26b&vxp=mtr There are plenty of pregen cables running around, take your pick. The whole set would cost around $30-$40. And get to lubing the cables, there a number of ways: MotionPro tool: http://www.motionpro.com/motorcycle/...FdcXgQod31IArg Cheap basically the same tool: http://www.ebay.com/itm/Universal-Mo...-/121142774160 Syringe method: http://www.pet360.com/product/52039/...FXQQ7AodQywAlA EZ Glide Tool: https://www.youtube.com/watch?v=rF43XTc3io8

March 16th, 2015, 07:29 AM	#9
ieathonda ninjette.org member Name: William Location: Houston Join Date: Feb 2015 Motorcycle(s): Ninja EX250F Posts: 110	ive noticed the clutch cable has nylon sheathing, would lubing it still be ok?