Replacing Clutch Cable Outer Without Removing Cover
Thread Starter
|
Intermediate
Joined: May 2017
Posts: 49
Likes: 0
From: Austin, TX
Replacing Clutch Cable Outer Without Removing Cover
Hi all,
I overfilled my transmission and the fluid is flowing into the clutch cable down by the transmission side cover. (I can see it because it's a braided cable/clear housing) I was not looking forward to replacing the entire cable again, but I had a thought as I closed up the garage: I think I can replace just the cable outern housing without having to remove the side cover.
I made the cable myself using a "build your own" kit that uses a removable barrel on the lever end, so here is what I'm thinking: I could disconnect the cable from the lever, lay it out "straight" from the side cover forward, remove the lever end barrel, thread the lower end of the housing out of the side cover, slide the outer off of the wire, fab up a new outer and reverse the removal process.
I think this will work and I won't have to deal with the side cover, clutch actuator circlips and all that...
Maybe?
Chris
I overfilled my transmission and the fluid is flowing into the clutch cable down by the transmission side cover. (I can see it because it's a braided cable/clear housing) I was not looking forward to replacing the entire cable again, but I had a thought as I closed up the garage: I think I can replace just the cable outern housing without having to remove the side cover.
I made the cable myself using a "build your own" kit that uses a removable barrel on the lever end, so here is what I'm thinking: I could disconnect the cable from the lever, lay it out "straight" from the side cover forward, remove the lever end barrel, thread the lower end of the housing out of the side cover, slide the outer off of the wire, fab up a new outer and reverse the removal process.
I think this will work and I won't have to deal with the side cover, clutch actuator circlips and all that...
Maybe?
Chris
Seasoned HDF Member
Joined: Aug 2011
Posts: 11,814
Likes: 5,120
From: SW Ohio
The barrel end on an HD clutch cable takes a lot of stress; that sounds like a good way to walk home. As mentioned, if you aren't over filling the trans, the leak is probably the result of the o-ring at the trans end of the cable.
Thread Starter
|
Intermediate
Joined: May 2017
Posts: 49
Likes: 0
From: Austin, TX
Now I'm confused as well. I checked my lubricant inventory last night and I have a partial quart remaining of trans lube. My owners manual says to use 28oz of lube for a transmission refill. I'm usually very specific about things like that so I likely did only pour 28oz of lube into the transmission. That means it is likely not overfilled (unless 28oz is too much). Does lubricant live in the side cover even when the transmission is properly filled? The o-ring sits on the outer base of the threaded fitting crimped to the lower end of the cable. It would prevent fluid from leaking onto the ground, but not into the interior of the housing. I suppose that would require a "seal" around the wire in the cable. What is happening here? Do I have an internal engine issue that is allowing an abnormal internal leak? Pressure in the side cover that shouldn't be there?
Seasoned HDF Member
Joined: May 2008
Posts: 21,029
Likes: 12,550
From: South Carolina
Man...you are waaaay overthinking this.
You probably have a bad o ring on the cable, if you even have one since you built this out of some sort of diy thing...
WHAT are you working on?
You probably have a bad o ring on the cable, if you even have one since you built this out of some sort of diy thing...
WHAT are you working on?
Last edited by Dan89FLSTC; Mar 27, 2020 at 08:43 AM.
Tourer
Joined: Sep 2019
Posts: 430
Likes: 129
From: Harley ville
the amount is for a dry fill.
Now I'm confused as well. I checked my lubricant inventory last night and I have a partial quart remaining of trans lube. My owners manual says to use 28oz of lube for a transmission refill. I'm usually very specific about things like that so I likely did only pour 28oz of lube into the transmission. That means it is likely not overfilled (unless 28oz is too much). Does lubricant live in the side cover even when the transmission is properly filled? The o-ring sits on the outer base of the threaded fitting crimped to the lower end of the cable. It would prevent fluid from leaking onto the ground, but not into the interior of the housing. I suppose that would require a "seal" around the wire in the cable. What is happening here? Do I have an internal engine issue that is allowing an abnormal internal leak? Pressure in the side cover that shouldn't be there?
Trending Topics
Stellar HDF Member
Joined: Aug 2019
Posts: 3,063
Likes: 1,867
From: Unreconstructed
Tranny fluid is supposed to flow into the lower end of the cable housing, that's why there's an o-ring on it to keep it from leaking out.
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Southpaw Super Glide: A Left-Hand-Drive 1979 Harley FXE Built to Fit the Rider
Verdad Gallardo
The Best and Worst Harley-Davidson Moves of 2025
Verdad Gallardo
Thread
Thread Starter
Forum
Replies
Last Post
justmealwatts
Dyna Glide Models
20
Mar 27, 2020 09:00 AM
ricks 2004 fatboy
Primary/Transmission/Driveline/Clutch
2
Jan 5, 2010 12:47 AM