Hitchcocks Forum

About 5 months ago I purchased an english clutch cable which failed last week.Chatting around these cable failures are not uncommon. I think I know why.Working by eye I made a new nipple from brass drilled to 2mm mmmmmm thought I that looks too fine so opened it to 2.5mm. Started to fit it and it was like chucking a banana up the m62. When I measured my cable I found it to be 1.75mm diameter.So a little research throttle cum light clutch cable from another english supplier is 2mm and the option is to use 3mm diameter. Could I suggest that you examine current stocks as they may not be to the spec that you ordered .

I make my clutch cables out of very cheap Chinese front brake cables for bicycles. The nipple on the clutch end is perfect so I solder a brass cable end nipple on the other and always carry a spare. The post 56 style bullets are pretty heavy on the clutch cables whereas my 51 with the triple start thread actuator is light and very easy on cables.

Clutch cable failures not uncommon? You mean the clutch cables are rubbish too? Well thats just great, something else I've never yet managed to break in approx 100,000 Royal Enfield miles! Sometimes you guys here make ME feel like a failure for not busting my bikes!

Apparently lucky Johnny too, never had a clutch cable break on me either, over 60,000 miles on enfields. What are we doing wrong?

Johnny and Eddie: Love to know your secret, I have gone through three clutch cables in 19,000 miles (English, Indian, makes no difference). I always carry a spare. Bike is a 500 Classic, but used for daily commuting in London traffic, this may have something to do with it....? (Although they must have lots of traffic in India too...)
Cheers
TimG

Tim, no secret really, If the clutch and mechanism is set up correctly and the cable is routed in the best way you should be able to operate the clutch lever with little effort there for not over straining the inner cable. I can operate my clutch levers with just two fingers.
This is not just an Enfield thing, BSA and most 50s bikes, if the clutch is not set up correctly the cables will break. I Have ridden many Brit bikes where the clutch is so heavy to operate that after a few miles my left hand is acking, I showed a friend of mine how to set the clutch up on his BSA A10 which was fitted with a 6 spring clutch, not one of the easiest to set up and the clutch is now a pleasure to use and no strain on the cable that is being used.

god i,ve read some crap on here but this takes the cake,note clutch cables are not breaking due to bad routing more likely poor manufacture too much heat when being soldered anyone with cables that have lasted for millions of miles are very lucky and they must have been done right at the factory because you never had 1 break,anyway the non breaking cable i,d get a patent on that, mr h beware you,ll never sell a cable again when thats been invented what says you noel (ogri)

Well Grundy 12 I must be doing something right for my cables to last so long and on so many of the bikes I have owned, not CRAP but fact not luck. A BAD WORKMAN ALWAYS BLAMES HIS TOOLS.

hi jonny ,your enfields must be magic i,d love to see the cable routing that you adopt,also i have 2 bullets 1 with light clutch springs easilly opperated 10,000 miles no cable breakage ,then i have the other bullet 3 light springs 3 heavy clutch action not as light 3000 miles no cable breakage ,these are iron barrelled bullets ,electra lean burn models break cables ,routing as per the factory fact ,efi,s routing as factory break cables always at the nipple on the lever, as your so good at setting clutches and routing cables what do you suggest to these owners,route as per factory or as per jonny ?come up with a good answer and cure these ill,s ?

Hi Grunda
When cables are mass produced they are not individually soldered as you might do when you make one yourself. They are made by dipping into molten solder. This is often the cause of failure especially with throttle cables. Often the nipples are dipped too far into the solder and tins an inch or more of the cable, consequently the cable cannot bend properly at this point. With the throttle it makes it very difficult for the cable to follow the throttle drum and to a lesser extent the over tinning of the cable will effect the clutch cable life as the cable is pulled in a very shallow arc. Like Johnny I have no trouble with clutch cables.
Regards
Edward