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Old 04-29-2009, 09:20 PM   #1 (permalink)
wildbillnc
 
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Question Need Help Clutch Cable install

Well I installed a new clutch cable and as soon as I installed the side plate cable was attached to, clutch lever was real hard to pull and had no play with cable adjusted to shortest lenght I check to make sure cable was on the right side of the dip stick but stiil had problem what else shpuld I check!
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Old 04-29-2009, 09:30 PM   #2 (permalink)
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Make sure you put the ball ramp that holds the cable in the position AFTER the casting in the cover, and not before it, where it'll hit, stop and bind. It sounds like you have it too far back, hence the cable slack all taken up.
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Old 04-29-2009, 09:34 PM   #3 (permalink)
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Seems like the balls would only line up with one position
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2003 Electra Glide Clasic
95" Se flat top pistons
Hillside Cycle Stage Three Heads
SE Adjustable Push Rods
Wood TW6G Cams
D&D Fatcat 2 into 1
103HP
106 Torq.
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Old 04-30-2009, 06:31 AM   #4 (permalink)
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I would take the cover off again and make sure that the ball and ramps are installed correctly and are moving freely. Make sure there is no rubbing taking place with the cable where it attaches to the arm on the top ramp.

And........did you compare the cable lengths just to make sure they are the same length?

Steve
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95" Powered by Big Boyz Heads, Woods Cams, Doherty PowerPacc w/ Powervents,
10:1 CR, D&D Fatcat 2-1 QB, Hillside 46.5mm TB, & Cometic Gaskets
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Old 04-30-2009, 07:19 AM   #5 (permalink)
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I just replaced my clutch cable on my 09. Maybe the 6speeds are different but I didn't have to disassemble all that stuff. I did take the cover off and thread in the new cable but I was able to get the end of the cable to curve around enough to hook it on, no problem. I just adjusted the cable all the way loose and didn't have it hooked to the controls until I had it in.

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Old 04-30-2009, 01:17 PM   #6 (permalink)
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I think I fiqured it out I think the free wire length is to short I talked with Hill Country Cylcles about the cable they said that they use this cable all the time! (Iguess there is enough variation in manufacturing to allow this cable to work some time), I also talked with Motion Pro the manufacturer and they said the free wire length on the cable I have is .40" to short for my application will find out tonight when I install a Harley cable
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2003 Electra Glide Clasic
95" Se flat top pistons
Hillside Cycle Stage Three Heads
SE Adjustable Push Rods
Wood TW6G Cams
D&D Fatcat 2 into 1
103HP
106 Torq.
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Old 04-30-2009, 06:25 PM   #7 (permalink)
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Be careful NOT to tighten the cable too tight at the housing (damaging the "o" ring seal). It will leak if you do.
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Old 05-01-2009, 07:31 AM   #8 (permalink)
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Ok the cable was the problem so beware if you change cables check the free wire length and make sure they are the same. The way to check is slide cable all the way to one end of the outer case and measure the wire end (free wire) this is very importatant you will have to be able to make them the same if you can't then don't install that cable. Thanks for your input!!
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2003 Electra Glide Clasic
95" Se flat top pistons
Hillside Cycle Stage Three Heads
SE Adjustable Push Rods
Wood TW6G Cams
D&D Fatcat 2 into 1
103HP
106 Torq.
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Old 05-01-2009, 02:06 PM   #9 (permalink)
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Glad it was something simple.

Steve
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2005 Harley Davidson Electra Glide Ultra Classic FLHTCUI
--------------------------------

95" Powered by Big Boyz Heads, Woods Cams, Doherty PowerPacc w/ Powervents,
10:1 CR, D&D Fatcat 2-1 QB, Hillside 46.5mm TB, & Cometic Gaskets
Built by Me, Tuned by Bean
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