Boxerworks.com

Since you guys had the magic answer to my previously posted charging system problem, I'll throw another one at you.

Third clutch cable in 4000 miles. They are failing adjacent to the lever, about 1/2 from the grab lug.
Subsequent to my last replacement, I have been super lubricating the area, but is there possiby some other
simple answer?

thanks

Sounds like you have a major misaligment with some hard rubbing that lube won't stop

so with out photos no clue

Nothing to align.
The clutch lever assembly directs the cable straight into the attachment point.

Probably is OEM.
No BMW dealer in my area.
My mechanic orders parts from a BMW dealer in another city.
It is actually quite remarkable that BMW still provides parts service on a 28 year old product.

A according to Tom cutter, some recent clutch cables have a hexaginol crimping next tothe nipple, this needs to be filed so it does not catch.

Slowly pull the clutch cable and watch the action of the cable relative to the handle. The cable barrel end must rotate in the handle so that the cable remains straight with no bending. If you see any bending in that last 1/2 inch of cable, then investigate to find out why. As has been suggested, there are several reasons for this problem.

Kurt in S.A.

Many times I have seen defects in the cable that would require dressing down to make them rotate smoothly. This is easy to test. It is the same test for lubrication.

Slowly pull the lever back. The slower the better. If you see it move in jerks, you have a problem. The ball/barrell should move perfectly freely. In a few cases I have even seen a lever have the defect. Fix it.

An owner should get in the habit of performing this test on both levers before every long ride. It only takes a few seconds, so why not?

Back in the day, our cables required lube too. If you are holding up a new cable vertically, the inner wire should drop of its own weight. I don't know about these new cables with an inner sheath.

I have exactly this problem with my R90/6 after I replaced the clutch lever, I will need to do some investigation, but in my case the problem will most probably be in the new lever, new nipple area.

Grease the round cable pivot on a regular basis, like Steve mentioned above, and it should last for many years. It's very common to break at this point if it can't pivot. I'm at 30k on my Motobins non OEM cable and expect it to go for another 30k at least.