06 Ultra clutch cable replacement
Thread Starter
|
6th Gear
Joined: Apr 2009
Posts: 12
Likes: 0
06 Ultra clutch cable replacement
I am looking for any info, shy of spending $60.00 for the service manual, on how to replace the clutch cable on an 06 Ultra. I have already purchased the cable, the gasket, and the "o" ring. I've been reading the forum for a few years now and see lots of great knowledge out there.
Seasoned HDF Member
Joined: Jun 2006
Posts: 28,520
Likes: 3,953
From: Vermont
The new cable should've come with an o-ring already on it. You will also need pn#11143 retaining ring for the clevis pin that holds the clutch lever in the perch. You will also need exhaust gaskets as you will have to drop the exhaust to get the tranny side cover off. You will not have to drain the transmission fluid if you put your scoot's tires up on 2x4 or 2x6 lumber and lean it way over to the left on the jiffy stand as the tranny fluid will flow to the left of the tranny. You will first need to collapse the adjuster on the cable at the downtube (back the jam nut off and unscrew it all the way, then unscrew the adjust all the way until there is total play in the lever). Once done, pop off the retaining ring from the clevis pin and remove it. Pull out the lever and unhook the cable. You will have to remove the outer fairing. The cable is also ziptied to the left fairing bracket and you will have to cut the ziptie. Pull the cable out through the fairing and then cut the ziptie at the downtubes. Look to see how your cable is routed prior to pulling it off the tubes (in front or behind the engine guard). Pull it back through by the rear master cylinder and to the point where it enters the side cover. Now you can pull off the side cover and remove it from there. You will need a good size snap ring plier to remove the retaining ring. Prior to removal look as to how it is positioned in there. Remove it and watch out you don't lose the 3 little ***** from the ball and ramp assembly. Install new cable and reverse the procedure. Prior to adjusting the cable, I would recommend a full clutch adjustment at the clutch basket especially since it is a new cable. Do a 1/2 turn back on the adjuster screw and a nickel's width for play at the ferrule on the lever. Prior to adjusting the cable also be sure and squeeze the lever 3 times or so to seat the ball and ramp assembly......have fun.
Club Member
Joined: Sep 2010
Posts: 1,689
Likes: 457
Nice write up Dawg. I've found that the 60 dollar cost of the service manual was worth every penny. If you plan on doing your own service, repairs and upgrades it will save you a lot of headaches. JMO. Good luck on the clutch cable.
Advanced
Joined: May 2011
Posts: 61
Likes: 0
From: Mi
Don't be so cheap....spend the money for the SM, then you'll be able to do all kindz o' **** wifout havin' to waste your time & others' as well
Trending Topics
Cruiser
Joined: Jun 2012
Posts: 216
Likes: 0
From: utah
I had a place bookmarked to buy a service manual but lost it. does anyone know where on line I can get one on line 
HD Forum Stories
The Best of Harley-Davidson for Lifelong Riders
7 Surprising Harley-Davidson Products that Are Not Motorcycles
Verdad Gallardo
8 Best Harley-Davidson Motorcycles Ever
Pouria Savadkouei
10 Worst Harley-Davidson Motorcycles Ever
Pouria Savadkouei
Killer Custom's Jail Break Is The Breakout That Refused to Blend In
Verdad Gallardo
Crazy Bunderbike Build Looks Amazing, But Is It Impossible to Ride?
Verdad Gallardo
Harley-Davidson Reveals Super Cool Cafe Racer Concept
Verdad Gallardo
Engraved Rebellion: Inside Bundnerbike's Glam Rock II
Verdad Gallardo
10 Motorcycles You Should Never Buy
Joe Kucinski
10 Things Harley-Davidson Needs to Fix in 2026
Verdad Gallardo
Elite HDF Member
Joined: Oct 2010
Posts: 3,504
Likes: 12
From: DOWN SOUTH
There are tons of places to get one online, just google it. By the time you pay for shipping to your door, you would probably be better off just going to the dealer and picking one up. Here is where I use. http://www.surdyke.com/
Stage I
Joined: May 2013
Posts: 1
Likes: 0
From: Gainesville, Georgia
Clutch cable replacement
I rode out this past weekend to a vet cemetery and lost my clutch in the process. It came completely loose and my grip just flops. I'm under the impression it came loose internally. Should I completely replace it? Or check it completely out from top to bottom before purchasing the parts?. I'm pretty pissed off because I've only been on my bike a half dozen times after spending a ton of money including a 56 point check. Any help/comments/advise ?
I have a 05 ultra classic
Thanks
I have a 05 ultra classic
Thanks
Thread
Thread Starter
Forum
Replies
Last Post
