Clutch Cable HEelp
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Road Warrior
Joined: Apr 2008
Posts: 1,393
Likes: 8
From: Ohio
Clutch Cable HEelp
I don't get this one: Replaced my clutch cable with the same cable (old one was worn and weeping at the bottom). I can't get any action from it. I backed out the adjuster screw on the clutchpack, turned it back in until it touched, then backed it out a 1/2 turn. When I take the slack out of the clutch cable adjuster, the clutch feels like it is pulling against a stop. No spring feel, just tight. I have all the ***** under the plate, but they sure felt like they were rolling all around under there when I turned the cover vertical to re-mount it. The manual doesn't have a lot of detail, doesn't even mention the *****. Do you have to keep the ***** in the ramps when you re-install the plate inside the cover? I thought they would seat after you pulled the lever a couple times and released it quickly. Does anyone have a step-by-step for clutch cable removal? Thanks.
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Road Warrior
Joined: Apr 2008
Posts: 1,393
Likes: 8
From: Ohio
Found the outer ramp at the bottom of the container I drained the fluid from the cover into. The exploded parts diagrams off of bikebandit clued me in. Oops. I think I should be able to get it back together tomorrow. Painful.
Last edited by BluBob; Oct 15, 2011 at 07:14 PM.
Ultimate HDF Member
Joined: May 2008
Posts: 6,642
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From: Ogden, UT
FYI for others and next time,
Unless you have some type of clutch tension reducer, you do not need to remove the plate inside the cover at all to replace the cable. Personally I never adjust the clutch pack unless it actually needs it, no need to touch it either if just replacing the cable.
Unless you have some type of clutch tension reducer, you do not need to remove the plate inside the cover at all to replace the cable. Personally I never adjust the clutch pack unless it actually needs it, no need to touch it either if just replacing the cable.
Outstanding HDF Member
Joined: Nov 2009
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From: TEXAS
interesting
i have changed out my cable several times( I have like three sets of bars and am always changing them) and I have tried to unhook the cable without taking apart the ramp but have never been able to do it
mine is an 06 i wonder if it is different than an 05
i have changed out my cable several times( I have like three sets of bars and am always changing them) and I have tried to unhook the cable without taking apart the ramp but have never been able to do it
mine is an 06 i wonder if it is different than an 05
Ultimate HDF Member
Joined: May 2008
Posts: 6,642
Likes: 48
From: Ogden, UT
I have worked on clutches up to and including 09 without having to take everything apart, only exception has been if it had a tension reducer.
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tips & tricks on clutch cable replacement
Did a clutch cable swap March this year. Due to the Easy pull clutch kit I had to take out the snap ring with a pair of snap ring pliers:
When installing the new clutch cable into the cover be careful not to damage the threads in the clutch release cover. Here's how I managed to get in the clutch cable without any problems:
1. I hung the clutch cable from the ceiling in my garage using a string
2. Sat underneath it with the clutch release cover between my knees
3. Grabbed the threaded end of the clutch cable, inserted the cable end into the threaded hole and positioned the cable in line with the cover
4. Once the two threaded parts get together, I first slowly turned the cable counter clockwise until I felt the threads falling together
5. From that point I slowly turned the cable's threaded end clockwise. When you don't feel any resistance you're OK!
When installing the new clutch cable into the cover be careful not to damage the threads in the clutch release cover. Here's how I managed to get in the clutch cable without any problems:
1. I hung the clutch cable from the ceiling in my garage using a string
2. Sat underneath it with the clutch release cover between my knees
3. Grabbed the threaded end of the clutch cable, inserted the cable end into the threaded hole and positioned the cable in line with the cover
4. Once the two threaded parts get together, I first slowly turned the cable counter clockwise until I felt the threads falling together
5. From that point I slowly turned the cable's threaded end clockwise. When you don't feel any resistance you're OK!
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Thread Starter
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Road Warrior
Joined: Apr 2008
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Likes: 8
From: Ohio
I got it back together this morning. It works great. A big difference with a new cable and the SE clutch spring. Definitely not an easy pull, but very positive. Now for a cam this winter.........
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Road Warrior
Joined: Apr 2008
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From: Ohio
It's me a couple years ago. M4 with an ACOG and J-point on it, IIRC. Great all-around setup, but with lights, sights, lasers, and batteries for all, you turn an eight pound tool into an 11 pound piece pretty quick.