New clutch cable issue.

buckshot85

New member
Aug 18, 2013
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Question for the clutch guys. I replaced the clutch cable with an HD Diamondback cable that is 4" longer to fit the new bars. I followed the service manual for the clutch adjustment. I added slack to the cable. Pulled the derby cover, loosened the jam nut and seated the screw lightly. Backed it out 3/4 of a turn. tightened the jam nut 102 in lb.. That seems awful light though. Is that right? Then I took up the slack with the cable adjustment. I pulled on the cable ferrule by the controls and have about 1/16" slack. The parts guy told me the new cable was lubed so I did not lube it. I also installed a new tranny side cover. I'm fairly certain I got the balls and ramps together just fine. After the snap ring was in place I had a little slop between the ramp plate and the snap ring for movement.

Question: My clutch lever feels awful heavy. I just got back from the dealer after returning some parts and while there I grabbed on to a couple used bike clutch levers to compare. They are like butter. Could cable lube be the issue? I started the bike and it shifts into first and let the clutch out and I feel it grab ahold and want to go. It does not come away from the grip much before grabbing, about 3/8" tops. I have no sharp bends in the cable. It is routed in the same manner as the original cable. I do not remember my clutch feeling this heavy.
 
I installed a diamond cable in a 2001 electraglide... was very hard to pull as well. I tried everything to get it to loosen up on the pull... no luck.

He brought it to HD for a 30k service and now it's like butter.. I wish I knew what they did different than me so I can help you out....

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About a week... I do know they went into the housing though... they charged him for a new gasket. He called me after he got the bike back to feel the clutch... I couldn't believe it. As you know... swapping this cable is not rocket science. I removed the cover... popped the snapring... unscrewed old cable... inserted and screwed new cable into housing... seated the cable and installed the snapring.

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Pull the thing back apart, while it's open lube the cable. Seating those balls can be tricky if it was your first time.
 
Pulled the cable from the handlebar housing and lubed it. Didn't help. Loosened the cable adjustment, pulled the derby cover and readjusted the clutch set screw and then took up the slack again in the cable. Bingo. Like butter. I think the balls and rings were not seated enough yet when I adjusted it the first time. Now it feels great. I was reluctant to pull the side cover because I knew the rings and rollers went in right. Finished now and it feels pretty good. Can't wait to ride it. Thanks guys for all the input and help.
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Glad you got it figured out

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I learned something just watching this thread - Thx guys!
 
Just noticed something.... we have the same taste in decor... LOL!!!

Your garage...

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My garage....

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:cool:
 
Hey buckshot, was that a Condor wheel chock in that pic, and if so how do you like it. Looking for one for the shop.
 
Gunner, I think so. Will check when I get home.

Spazz, the more I think about it, I think I stole the Hog banner decorating idea from you. I think I saw it in pic of your garage a while ago.
 
I got the idea from a friend...looks cool when doors are up with the orange and black hangin

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Gunner, the chock is a Condor. I do like it. I run the bike on it and that's how I store the bike for the winter. No jiffy stand or anything. It stays pretty solid. A bitch for short legs to get it off of it at times.
 


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