CLUTCH CABLE INSTALL PROBLEM
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5th Gear
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CLUTCH CABLE INSTALL PROBLEM
I just replacedthe bars on my '07 FLHX with Wild1 bagger bars and am running into a clutch adjustment problem. I adjusted the clutch as per the service manual, but it's wasn't engaging fully. I noticed a little too much play at the lever and took it up in the cable. When I tried the lever again it was still tough and I heard a pop a then a release in the lever. Any suggestions? My gut feel is that it's the ball/ramp set-up, but hate to deal with the exhaust and tranny fluid again. I was hoping someone here can give me a heads up to save some head-aches. I originally stayed with the stock cable, but switched to a 4" over Barnett. Any help appreciated!
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RE: CLUTCH CABLE INSTALL PROBLEM
You don't have to worry about the tranny fluid to check the ball and ramps. Just drop the exhaust and then put a 2x4 under each tire and lean your bike over onto the side stand. You can then remove the clutch side cover without any tranny fluid coming out because it all goes to the left side. This is what I did when I put on my EZ clutch.
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RE: CLUTCH CABLE INSTALL PROBLEM
I just went through exactly the same thing installing the 513s on my RKC. Here's what you've got.....the lever pull is real, real tough, with no movement, then the cable pops right at the lever, right?
I looked into the clutch release cover (through the tranny dipstick hole) and the clutch cable was full forward on the arm on the inner ramp, indicating to me there was no way there was any available cable to pull in. I removed the exhaust and clutch release cover AGAIN, freed up more cable at the mid-cable adjuster and reset the ball and ramp setup 120 degrees back, solving the problem.
To avoid having to do what I went through though, I'd suggest you first go under the derby cover and see if you can't resolve it by backing off the adjuster there. Here's why.....after I was done resolving the issue from the right side of the bike, I went back under the derby cover in an attempt to fine-tune the clutch setup. What I discovered was that I was able to duplicate the issue all over again from the derby side by driving the adjuster in too far. This has made me wonder if I couldn't have avoided yanking off the exhaust and clutch release cover the 2nd time, and fixed it from the left side the first time around.
If this fails, go back in the right side, give yourself more cable inside the cover to allow you to set the arm on the inner ramp back 120 degrees.
I feel your pain. Hopefully you can avoid some of what I went through.
CN
I looked into the clutch release cover (through the tranny dipstick hole) and the clutch cable was full forward on the arm on the inner ramp, indicating to me there was no way there was any available cable to pull in. I removed the exhaust and clutch release cover AGAIN, freed up more cable at the mid-cable adjuster and reset the ball and ramp setup 120 degrees back, solving the problem.
To avoid having to do what I went through though, I'd suggest you first go under the derby cover and see if you can't resolve it by backing off the adjuster there. Here's why.....after I was done resolving the issue from the right side of the bike, I went back under the derby cover in an attempt to fine-tune the clutch setup. What I discovered was that I was able to duplicate the issue all over again from the derby side by driving the adjuster in too far. This has made me wonder if I couldn't have avoided yanking off the exhaust and clutch release cover the 2nd time, and fixed it from the left side the first time around.
If this fails, go back in the right side, give yourself more cable inside the cover to allow you to set the arm on the inner ramp back 120 degrees.
I feel your pain. Hopefully you can avoid some of what I went through.
CN
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From: Vancouver, B.C.
RE: CLUTCH CABLE INSTALL PROBLEM
You don't have to worry about the tranny fluid to check the ball and ramps.
CN
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5th Gear
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RE: CLUTCH CABLE INSTALL PROBLEM
Thanks for the info. The manual says to set the mechanism by pulling the lever a maximum of three times prior to adjusting the cable. I think that's where this isn't setting up properly. Hopefully I can get it right behind the derby cover and not have to pull the tranny cover. Thanks for the tip about not draining the fluid!
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5th Gear
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RE: CLUTCH CABLE INSTALL PROBLEM
Back at it this AM. I took off the tranny cover, made sure the ***** and ramp were properly set,adjusted as per manual, but lever is still tough! Service manual says to lightly seat the adjuster screw, does that mean just make firm contact?? I back it out about 3/4 turn then tighten the locknut. After taking up the slack the lever is still very stiff, and when I bear down I hear a pop and it gives. Can't understand the problem, i've done a bunch of these on previous bikes. Any suggestions?
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From: Vancouver, B.C.
RE: CLUTCH CABLE INSTALL PROBLEM
Is the ball and ramp set to where there is a pull available on the cable?
When I put the ball and ramp assembly into the cover on mine, I set it where the arm and cable connectorwere so far over towards where the cable comes into the cover that there was no way the lever could move the assembly 'cause it was at the "full pulled" position.You ought to have been able to see if this was the case just by looking into the dipstick hole.
My solution was to free up more cable into the cover and set the inner ramp back 120 degrees on the outer ramp.
CN
When I put the ball and ramp assembly into the cover on mine, I set it where the arm and cable connectorwere so far over towards where the cable comes into the cover that there was no way the lever could move the assembly 'cause it was at the "full pulled" position.You ought to have been able to see if this was the case just by looking into the dipstick hole.
My solution was to free up more cable into the cover and set the inner ramp back 120 degrees on the outer ramp.
CN
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5th Gear
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RE: CLUTCH CABLE INSTALL PROBLEM
That's what I thought I did this AM, but when all buttoned up, same problem. I will tackle it again this evening with a little more patience. I reall wanted to ride this evening because the cops set up a gauntlet there last week and harassed alot of people. Lots of tickets regarding equipment, helmets ect... If you didnt have a M/C endorsement they impounded your bike and took you to jail. I'm 100% legal but infuriated over the harassment! Oh well, maybe It's better I'm in my garage tonite, my mouth and opinion might get me in trouble otherwise!
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5th Gear
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RE: CLUTCH CABLE INSTALL PROBLEM
Well I found the problem! Using the stock cable. I cracked the lip that secures the retaing ring inside the cover. Once again taking time reading my manual helped. I had been starting at assembly, not cleaning and inspection! I followed the manual, inspected everything, and viola. Good news is the cover was in stock at the dealer for $89.95 less a 10% HOG discount. A cheap leeon learned.
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