Lower Clutch cable removal
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Joined: Feb 2007
Posts: 16,320
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From: Boynton Beach, FloriDuh
There is no "lower" clutch cable. It's a single cable with an adjuster in the middle.
Honestly, after all the posts about the primary cover, IMO you need to consider buying the Service Manual. You're going to need it for the clutch adjustments.
Honestly, after all the posts about the primary cover, IMO you need to consider buying the Service Manual. You're going to need it for the clutch adjustments.
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Joined: Jan 2009
Posts: 1,551
Likes: 6
Well......in the service manual that you suggested he fetch, they call it the lower clutch cable....just sayin.
Original poster, I just swapped a clutch cable for my bud yesterday, and I too suggest you get the manual, but odds are you ain't gonna breeze into a dealer and snag one . They will usually have to order a manual for you.
That said, first drain oil from primary, remove lever and clamp from handle bar, relax cable adjustment fully, remove cable from lever, remove derby cover, remove spring and locking nut inside derby cover, with a narrow blade screwdriver twist clutch center screw until ball ramp assembly falls free in your hand then rotate ball ramp assembly backwards until cable end comes free taking care not to drop cable end adapter into primary case......from there allow cable to lay straight out alongside front wheel while you wrench the lower end of the cable from the primary.
Reassembly is the reverse, but you gotta make certain not to cross thread the cable into the primary plus DO NOT overtighten the cable to primary or you WILL break the threaded end off the cable.
Oh, good time to adjust primary chain...And don't forget to refill primary with 1 qt of oil.
All that's left is clutch release(ball ramp assembly) adjustment and cable adjustment, then you can reinstall the derby cover.
Each of these steps require certain knowlege and skills/tricks not found in any book or manual....Just getting the derby gasket to seal can be a challenge.
Yeah, get a book first or hire a guy who knows what he is doing and watch him as he explains while he does it. There is lots to go wrong and you can believe it will go wrong if you risk it.
P.S. Glad you got your son a Sportster and are attempting to help him mod it.....Don't be intimidated.....well, don't let him see you intimidated.
Original poster, I just swapped a clutch cable for my bud yesterday, and I too suggest you get the manual, but odds are you ain't gonna breeze into a dealer and snag one . They will usually have to order a manual for you.
That said, first drain oil from primary, remove lever and clamp from handle bar, relax cable adjustment fully, remove cable from lever, remove derby cover, remove spring and locking nut inside derby cover, with a narrow blade screwdriver twist clutch center screw until ball ramp assembly falls free in your hand then rotate ball ramp assembly backwards until cable end comes free taking care not to drop cable end adapter into primary case......from there allow cable to lay straight out alongside front wheel while you wrench the lower end of the cable from the primary.
Reassembly is the reverse, but you gotta make certain not to cross thread the cable into the primary plus DO NOT overtighten the cable to primary or you WILL break the threaded end off the cable.
Oh, good time to adjust primary chain...And don't forget to refill primary with 1 qt of oil.
All that's left is clutch release(ball ramp assembly) adjustment and cable adjustment, then you can reinstall the derby cover.
Each of these steps require certain knowlege and skills/tricks not found in any book or manual....Just getting the derby gasket to seal can be a challenge.
Yeah, get a book first or hire a guy who knows what he is doing and watch him as he explains while he does it. There is lots to go wrong and you can believe it will go wrong if you risk it.
P.S. Glad you got your son a Sportster and are attempting to help him mod it.....Don't be intimidated.....well, don't let him see you intimidated.
Last edited by oinker02; Aug 26, 2009 at 04:18 AM.
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