clutch cable keeps breaking

For the second time in about 18 months my clutch cable popped on a '77 KZ650c. It's the head of the cable that pulls off. There's got to be something gnawing at it but I can't see it. Anyone have the same experience? Suggestions? I'm getting tired of surprises that leave me stuck.

I've owned my 1977 KZ650-C1 for 39 years and never had a cable break. Are you using genuine Kawasaki cables or aftermarket? Also, make sure you lube the new cable before installing and ensure it is routed properly (no kinks) and that the inner cable isn't rubbing the adjuster at the lever. Properly adjust the clutch (at all 3 places) and make sure the clutch release is lubed. The clutch should not require much effort to pull in and the cable should last for decades. Ed

Was it a motion pro by any chance?
Steve

In 168,000 miles on my 78 Kz650B, I haven't kept track of how many clutch cable failures, but if I had to guess I would say 10, so about 16,000 per cable estimate. I always used stock Kawasaki cables until they quit making them on this motorcycle. Later running motion pro cables on another KZ650 it seems 16,000 is still about the norm. They will always break right at the lever without exception. No huge deal, 1/2hr to change cable every year or two. No clutch cable failure got me stuck. Use your legs to get moving, then shift up and down by letting off the throttle. Shift to neutral at stops. I've ridden many a mile with no clutch on a KZ650 even with a passenger. Have to work a little in technique is all.

You may want to consider another lever perch, it may be worn. VN800 clutch cables have a hard plastic bushing on the cable head. Being a Vtwin though I don't recall it having the same amount of steel wire for pipe protection. I am not sure if witha VN800 lever you could get the bushing seperate. With over 90000 mile on VN800 I only had one cable break. Mmmmm. R

Yes, when mine broke it was at the lever as well. So now every winter I loosen the cable and remove it from the lever and clean it out. Road grime can get in there and act as a grinding wheel. Make sure the lever, where the cable end pivots, is smooth and free of dirt. Or any flashing. Inspect the cable ball ends and if you see any fraying, it's time to replace, True with any cable.
Maintenance is a good thing. Mmmmm.... I just saw that somewhere

Be sure to lubricate the lever & lever end with a good lubricant that isn't easily washed away. Also, inspect the lever & cable end for burrs or anything & sand them down as necessary. I've seen some old topics in the Archives in which some motion pro cables weren't smooth enough on the ends, so they would bind & break.

OR JUST PLAIN CHEAP.
Steve

No eBay APP ID and/or Cert ID defined in Kunena configurationI don't recall if it was a motion pro but it was cheap, like $12 or something, so that could be it. And, my buddy and i put it on and did none of the suggestions of lubeing, etc. So yeah, I'll do them.

Any old Motion Pro will do, like this one?

I've had it with Motion Pro. Seems they're made in CHINA. I'll buy a OEM or something I know is made here even if it costs twice as much.
Steve
BTW, I may have helped mine last longer with this.
kzrider.com/forum/2-engine/601798-clutch-actuator-mod

which lubricant might you recommend?

This method works well for me; I have never had a cable break on my KZ650. I make a little funnel using Saran Wrap and using twist ties I attach it to the upper end of the cable. I also Saran Wrap the center adjuster and twist tie it at both ends so oil won’t leak there. Then I hang the upper end of the cable and put a couple teaspoons of synthetic motor oil in the funnel. I put a catch pan under the bottom end. After it hangs over night the entire inside of the cable is lubed and the Saran Wrap can be removed. You can use some lithium grease on the ends of the cables, but it is also important to see how the cable interacts with the top adjuster and make sure the inner cable is not rubbing on anything that can abrade it. I lube the throttle cables the same way. Ed