Clutch cable replacement
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Cruiser
Joined: Oct 2005
Posts: 220
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Clutch cable replacement
Hello all, I was going to attempt the clutch cable replacement today as part of my new handle bar replacement. I did alot of searching but came up with nothing here for threads talking about how this is accomplished. I had a good mental image of what I thought I would need to do but it appears that i may have to take the right side exhaust off the bike. That may just be above my mechanic level.
Can I get some advise on this? does it indeed need to come off? and what ever else you can enlighten me on for this task would be greatly appreciated.
Thanks as always
Harpoon
Can I get some advise on this? does it indeed need to come off? and what ever else you can enlighten me on for this task would be greatly appreciated.
Thanks as always
Harpoon
Seasoned HDF Member
Joined: Sep 2005
Posts: 5,072
Likes: 104
From: Prescott, AZ
RE: Clutch cable replacement
Best advice is to buy a Manual for your bike - the clutch swap is not all that easy - however, after you do it once - next time will not take as long... exhaust has to come off and it does take time... buy the manual..
Seasoned HDF Member
Joined: Jun 2006
Posts: 28,514
Likes: 3,951
From: Vermont
RE: Clutch cable replacement
Since you have the stockcrossover pipe, you'll have to take the whole shibang off. Best bet is to put each wheel of bike up onto 2x4's or 2x6's and lean it way over to the left on the jiffy stand. This will allow all of the tranny fluid to settle to the left and when you take off the tranny side cover you will not lose any fluid, but maybe a drop. This will save you from having to drain and replace the tranny fluid. Since you don't have a fairing, the rest is easy. You will need two exhaust gaskets, a tranny side cover gasket and the new cable. If the cable does not come with a retaining ring for the clevis pin then you will also need one of them. Collapse the adjuster all the way to loosen all the slack in the clutch cable. Then take it out of the perch by taking the retaining ring off with snap ring pliers and unhooking the cable from the handle. Cut the ziptie that holds the cable to the downtube and then remove it from the ball and ramp assembly inside the tranny side cover.
Grand HDF Member
Joined: Sep 2005
Posts: 4,890
Likes: 73
From: MA
RE: Clutch cable replacement
ORIGINAL: dawg
Since you have the stockcrossover pipe, you'll have to take the whole shibang off. Best bet is to put each wheel of bike up onto 2x4's or 2x6's and lean it way over to the left on the jiffy stand. This will allow all of the tranny fluid to settle to the left and when you take off the tranny side cover you will not lose any fluid, but maybe a drop. This will save you from having to drain and replace the tranny fluid. Since you don't have a fairing, the rest is easy. You will need two exhaust gaskets, a tranny side cover gasket and the new cable. If the cable does not come with a retaining ring for the clevis pin then you will also need one of them. Collapse the adjuster all the way to loosen all the slack in the clutch cable. Then take it out of the perch by taking the retaining ring off with snap ring pliers and unhooking the cable from the handle. Cut the ziptie that holds the cable to the downtube and then remove it from the ball and ramp assembly inside the tranny side cover.
Since you have the stockcrossover pipe, you'll have to take the whole shibang off. Best bet is to put each wheel of bike up onto 2x4's or 2x6's and lean it way over to the left on the jiffy stand. This will allow all of the tranny fluid to settle to the left and when you take off the tranny side cover you will not lose any fluid, but maybe a drop. This will save you from having to drain and replace the tranny fluid. Since you don't have a fairing, the rest is easy. You will need two exhaust gaskets, a tranny side cover gasket and the new cable. If the cable does not come with a retaining ring for the clevis pin then you will also need one of them. Collapse the adjuster all the way to loosen all the slack in the clutch cable. Then take it out of the perch by taking the retaining ring off with snap ring pliers and unhooking the cable from the handle. Cut the ziptie that holds the cable to the downtube and then remove it from the ball and ramp assembly inside the tranny side cover.
Seasoned HDF Member
Joined: Jun 2006
Posts: 28,514
Likes: 3,951
From: Vermont
RE: Clutch cable replacement
ORIGINAL: soos
[sm=ttiwwp.gif]
ORIGINAL: dawg
Since you have the stockcrossover pipe, you'll have to take the whole shibang off. Best bet is to put each wheel of bike up onto 2x4's or 2x6's and lean it way over to the left on the jiffy stand. This will allow all of the tranny fluid to settle to the left and when you take off the tranny side cover you will not lose any fluid, but maybe a drop. This will save you from having to drain and replace the tranny fluid. Since you don't have a fairing, the rest is easy. You will need two exhaust gaskets, a tranny side cover gasket and the new cable. If the cable does not come with a retaining ring for the clevis pin then you will also need one of them. Collapse the adjuster all the way to loosen all the slack in the clutch cable. Then take it out of the perch by taking the retaining ring off with snap ring pliers and unhooking the cable from the handle. Cut the ziptie that holds the cable to the downtube and then remove it from the ball and ramp assembly inside the tranny side cover.
Since you have the stockcrossover pipe, you'll have to take the whole shibang off. Best bet is to put each wheel of bike up onto 2x4's or 2x6's and lean it way over to the left on the jiffy stand. This will allow all of the tranny fluid to settle to the left and when you take off the tranny side cover you will not lose any fluid, but maybe a drop. This will save you from having to drain and replace the tranny fluid. Since you don't have a fairing, the rest is easy. You will need two exhaust gaskets, a tranny side cover gasket and the new cable. If the cable does not come with a retaining ring for the clevis pin then you will also need one of them. Collapse the adjuster all the way to loosen all the slack in the clutch cable. Then take it out of the perch by taking the retaining ring off with snap ring pliers and unhooking the cable from the handle. Cut the ziptie that holds the cable to the downtube and then remove it from the ball and ramp assembly inside the tranny side cover.
Seems to me that you recently replaced a clutch cable and didn't take any pics[8D]
Grand HDF Member
Joined: Sep 2005
Posts: 4,890
Likes: 73
From: MA
RE: Clutch cable replacement
I was too busy pissin an' moanin'. Besides, you are the master...[sm=hail.gif][sm=hail.gif][sm=hail.gif][sm=hail.gif]
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Thread Starter
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Cruiser
Joined: Oct 2005
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RE: Clutch cable replacement
yes guys I have the manual so I will need to dive into that pretty thoroughly. Mann I am not sure about doing this now.. but not sure I have a choice since it is all ripped down and not ridable... There are soo many screws along the exhause and most of them are looking pretty rusty..
As for tipping the bike I just assumed I would drain the fluid and replace it, I thought that was the smart thing to do. Where is the drain plug though. I look all under that trans case and could't see any drain plug... it could be hidden by my jack though.....
Thanks,
Scared, non mechanic getting himself in trouble...
As for tipping the bike I just assumed I would drain the fluid and replace it, I thought that was the smart thing to do. Where is the drain plug though. I look all under that trans case and could't see any drain plug... it could be hidden by my jack though.....
Thanks,
Scared, non mechanic getting himself in trouble...
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Seasoned HDF Member
Joined: Jun 2006
Posts: 28,514
Likes: 3,951
From: Vermont
RE: Clutch cable replacement
Tranny drain plug pictured below. If ya drop and drain the fluid I believe for your year it calls for 20-24oz.....I always went with 22oz in the middle of the road.
[IMG]local://upfiles/13641/B24F02BAF52D427FA6EE5ABF4F32A715.jpg[/IMG]
[IMG]local://upfiles/13641/B24F02BAF52D427FA6EE5ABF4F32A715.jpg[/IMG]