I had the cable drop out during rush hour on the day of the Blue Angles airshow as it ended. Really bad timing.   Had 4 bikes, 1 pickup truck and 2 police officers stop and hangout while I worked on it. One officer followed me home to make sure I was ok. Was pretty cool of him. All in all for what could have been a really sucky time it turned out ok! 

So after I got it together I haven't had the problem again but I am keeping a close eye on it. I did a search on this happening. One school of thought was that the Lever wears unevenly and lets the cable drop out. That is why I am looking at new levers. May do the bush fix for temporary fix (screw and washer) as I am going to the Square route rally on the 6/3. Worry about it when I return.

Not sure what you are describing.  Are you saying the end of the cable fell out of the lever?  Can you post a photo?

Normally, the problem is that the cable breaks at the lever because the fitting on the end of the cable doesn't rotate when the lever is pulled, weakening the wire over time.  This is due to failure to lubricate where the end of the cable fits into the lever.  I keep a small oil can near my bikes, and every week when I check tire pressure, etc., I put a drop of oil on that fitting in the lever.

Hi, The end of the cable dropped out of the lever. I got it back in when it happened. Took a little bit of time but it did and does work. Checked the cable and it looks ok. 
I did a rig that if nothing else makes me feel better. Drilled a small hole in the underside of the lever. Used a very small self tapping screw that doesn't touch the cable end but won't allow the end to drop out and put it in. Lubricated cable end, works fine.
It was one of those hey this is probably one of the worst times for this to happen and it did. It did warm my heart that so many folks stopped to help though.

Thanks
Bill

fishboy316 wrote:I did a rig that if nothing else makes me feel better. Drilled a small hole in the underside of the lever. Used a very small self tapping screw that doesn't touch the cable end but won't allow the end to drop out and put it in.

That could be the groundwork for an unintended consequence. Would you please post a photo of that?

Ah. Somebody has opened the clutch lever out to 10mm to take a non-standard cable, but you have a standard cable (8mm barrel) in there. Get a replacement clutch lever asap.

When was the last time your moto's clutch was adjusted, fishboy, and how much free play is at the lever right now?

I plan on getting a new lever next week when I get back from the rally.  The clutch has worked very well so I haven't messed with it until the cable dropped out. Not sure about when was done before. Will measure the free play today.

Thanks

Measured out to 3/16" free play. Clutch feels good.

Dai wrote:Ah. Somebody has opened the clutch lever out to 10mm to take a non-standard cable, but you have a standard cable (8mm barrel) in there. Get a replacement clutch lever asap.

 That makes all the sense in the world after looking at the pic. She is still throwing curves. Relatively easy fix though. Little more money and a little more time.

Dai wrote:Ah. Somebody has opened the clutch lever out to 10mm to take a non-standard cable, but you have a standard cable (8mm barrel) in there. Get a replacement clutch lever asap.

GOOD EYE!