New clutch cable problem
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Cruiser
Joined: May 2013
Posts: 127
Likes: 1
From: Poynette, Wisconsin
New clutch cable problem
Just installed new clutch cable into the clutch release cover on my 2007 FLHTC and everything went on as it should after severely fighting the threads on the clutch housing with the new cable. The cable is fully adjusted down giving it maximum slack. The problem is I have no free play on the cable at all. It seems jammed up. The cable was moving freely in the housing and the three *****, sprocket, inner ramp and coupling. What could be hanging it up? Could there be something not lined up. There is an oil slinger in there. Is it possible that I could be getting hung up on that?
Novice
Joined: Aug 2013
Posts: 16
Likes: 2
From: East Coast
If/when I take the clutch cable out/install a new one... I pull the cover that it threads into (after breaking the cable nut loose first), route the cable leaving just the top unhooked... hook up the new cable, thread it in and make sure everything with the "3 baller" thing is right as you said you did... Cover goes on...
Bottom out the adjuster, take your lever off the hpusing if it's not already... Hook up the new cable with the little plast sleeve to the lever, mount lever to housing...
If the adjuster is bottomed out as you said yours is... make sure you've routed the cable properly and it's not pinched by the triple trees or anything else that'll cause the length of the cable to change as you turn the bars "lock to lock"...
If nothing is caught up, and your install is 100% correct.... Put a 2x4 under the kick stand and bottom out the adjuster (yours already is as you said), pull the derby/clutch inspection cover on the primary and follow the clutch adjustment that's floating around on the forum or you manual... You may wanna find a 11/16 "spark plug socket" before you start... that gives you the ability to tighten the lock nut in place while you hold the adjustment screw/allen wrench in place... It's tough to get a box wrench on the lock nut unless it has a bigger offset than a standard box wrench...
I'm not sure if I missed anything but lookup "your year/model" clutch adjustment... It's pretty easy but takes a few tries to get the feel for it...
If I left anything out or there's an easier way I'm sure someone will straighten me out but any issues; just post back...
Edit: after re-reading your post it sounds to me like the end of the cable (where it hooks to the 3 baller) may not be attached correctly to the 3-b'er or u may have routed incorrectly and be pinching it somewhere... I'm gonna go take a look at how my cable attaches to the actuator (3ber) n see what it looks like...
Bottom out the adjuster, take your lever off the hpusing if it's not already... Hook up the new cable with the little plast sleeve to the lever, mount lever to housing...
If the adjuster is bottomed out as you said yours is... make sure you've routed the cable properly and it's not pinched by the triple trees or anything else that'll cause the length of the cable to change as you turn the bars "lock to lock"...
If nothing is caught up, and your install is 100% correct.... Put a 2x4 under the kick stand and bottom out the adjuster (yours already is as you said), pull the derby/clutch inspection cover on the primary and follow the clutch adjustment that's floating around on the forum or you manual... You may wanna find a 11/16 "spark plug socket" before you start... that gives you the ability to tighten the lock nut in place while you hold the adjustment screw/allen wrench in place... It's tough to get a box wrench on the lock nut unless it has a bigger offset than a standard box wrench...
I'm not sure if I missed anything but lookup "your year/model" clutch adjustment... It's pretty easy but takes a few tries to get the feel for it...
If I left anything out or there's an easier way I'm sure someone will straighten me out but any issues; just post back...
Edit: after re-reading your post it sounds to me like the end of the cable (where it hooks to the 3 baller) may not be attached correctly to the 3-b'er or u may have routed incorrectly and be pinching it somewhere... I'm gonna go take a look at how my cable attaches to the actuator (3ber) n see what it looks like...
Last edited by whitey78; Jul 26, 2014 at 01:13 PM.
Novice
Joined: Aug 2013
Posts: 16
Likes: 2
From: East Coast
Here's a link to the video I had to take cuz I couldn't get a pic but if you look close at the last couple seconds after I pull the clutch cable you can see how the cable is supposed to connect at the actuator... It's 30 seconds but the last few is where you'll see it.. I've hooked it up wrong myself before and had the same issue I believe...
Novice
Joined: Jul 2014
Posts: 24
Likes: 0
From: Bay Area ca
When I did mine, it did the same thing. I loosened the cover back up slowly while working the lever end of the cable softly, and it just kinda popped in, and I was able to tighten the side case back down.
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tna1000
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Jul 25, 2007 09:26 PM
