Replacing clutch cable

[ChopperJeff]

I know all about getting the clutch cable out of the lever end of it all, but what's involved in getting it off of the pully cover end?

Also, if Nelson is out there and reading this, then plesae check your email as I PM'd you about getting a new clutch cable.

 

[Gas Man]

common question

made a how to for ya

http://www.bigdogbiker.com/forums/how/9516-how-replace-your-clutch-cable.html#post140327

 

[lee]

good work Chris

 

[Gas Man]

That took forever to find those pics throughout my many folders...

 

[jwoolf]

Nothing to it. Pull your pipes, pull the cover and, pull the 5 allen screws holding the little metal plate. There isn't much to it and, you can easily see how it's all put together once you get it apart. There's a thread also on adjusting the clutch on here somewhere that's worth a read too.

That's the only how-to I read. Just start taking shit apart and, you'll figure it out. I think I only paid like 65.00 for the cable too.

Doesn't take long at all to replace. I just replaced mine.

 

[Gas Man]

Jwolf is right... its pretty straight forward once you know how to do the adjustment. But sometimes some good pics will help the shy peeps

 

[stlmikie]

Talk about shy peeps. I didn't want to take off the little plate on my starter to stretch the spring.

 

[ChopperJeff]

Thanks guys for the input, and GasMan for the "How-To"!

Now all I need is a new clutch cable. Have yet to hear back from Nelson at WB Cycles. Hopefully I'll get a hold of him soon, but being the holiday season, maybe he's not around.

 

[Raywood]

Thanks guys for the input, and GasMan for the "How-To"!

Now all I need is a new clutch cable. Have yet to hear back from Nelson at WB Cycles. Hopefully I'll get a hold of him soon, but being the holiday season, maybe he's not around.

Hey, seems you could just run over to Arlen Ness and get one. Might be faster. You also have Rick Simms (formerly BACC) and lots of other custom shops. It's just a Barnett cable available anywhere.

 

[ChopperJeff]

Thanks Raywood, but I already called Alren Ness and they have none in stock. He told me though that one made for the Harley Softtail should work as long as it's a 4 inch over stock. I'm going to pull the old one off and see if it really matches up with a Harley one. I would sure like to get one from Nelson though.

 

[Raywood]

Thanks Raywood, but I already called Alren Ness and they have none in stock. He told me though that one made for the Harley Softtail should work as long as it's a 4 inch over stock. I'm going to pull the old one off and see if it really matches up with a Harley one. I would sure like to get one from Nelson though.

Hard to believe that the Ness shop doesn't have one of those with all the custom bikes they have. Sounds like its time for a new parts manager!!

 

[ChopperJeff]

Yeah, it does sound strange that a place that builds cutom bikes does not have a clutch cable laying around. I'll see about getting the Barnett cable from another place. Mayve the local Hraley carries them.

By the way, about the "How-To" on replacing the cable (by the way, I followed it got my cable off!). When dong the adustment of the push rod, it says "Screw rod in till you feel it touch the clutch plate". Does this mean that as soon as you feel any resistance, you should stop, then back it off, or do you actually go past that point until you can't titghten it any further. I'm pretty sure you're to stop once resistance is felt, but would like to make sure.

 

[woodbutcher]

stop when resistance is met.

 

[Gas Man]

just till you feel it give a definate touch. Then turn back. I usually repeat this a few times to ensure I get it right.

 

[ChopperJeff]

OK, thanks guys!!!

 

[Raywood]

When dong the adustment of the push rod, it says "Screw rod in till you feel it touch the clutch plate". Does this mean that as soon as you feel any resistance, you should stop, then back it off, or do you actually go past that point until you can't titghten it any further. I'm pretty sure you're to stop once resistance is felt, but would like to make sure.

This is where you get most of your adjustment. You should adjust it then try it then adjust it then try it till you get it to just where you want it.
I turn mine in slightly more than just touching. If the feel of it if you know what I mean. If you have a little play in your clutch pack then you will want to push it in a little bit more. Play with it till you get it just to where you want it.

Have fun,

 

[ChopperJeff]

Thanks Rayood! Sounds like it may end up being a bit more art than science, huh? So I guess the push rod gives you the gross adjustment, then the cable adjuster is where you fine tune it.

By the way, I managed to buy the Barnett clutch cable from Arlen Ness after all. I went over there and spoke with the same guy I had talked to on the phone before, and mentioned that it just seems strange that a place that builds bikes does not have any clutch cables. The look he got was like a dear in the headlights, and then says "damn, I keep forgetting that we've got parts upstairs". I then handed him my old cable and he comes back with a Barnett one with the exact same length. He apologized for not thinking of it earlier, but hey, I was happy to get the cable in my hands, so it didn't matter to me.

Now I got to get ahold of another ferrule. I KNEW I had to take care not losing that little thing, and then what do I do? Of course I proceed to lose it. It's always something! :bang:

 

[Raywood]

Thanks Rayood! Sounds like it may end up being a bit more art than science, huh? So I guess the push rod gives you the gross adjustment, then the cable adjuster is where you fine tune it.

By the way, I managed to buy the Barnett clutch cable from Arlen Ness after all. I went over there and spoke with the same guy I had talked to on the phone before, and mentioned that it just seems strange that a place that builds bikes does not have any clutch cables. The look he got was like a dear in the headlights, and then says "damn, I keep forgetting that we've got parts upstairs". I then handed him my old cable and he comes back with a Barnett one with the exact same length. He apologized for not thinking of it earlier, but hey, I was happy to get the cable in my hands, so it didn't matter to me.

Now I got to get ahold of another ferrule. I KNEW I had to take care not losing that little thing, and then what do I do? Of course I proceed to lose it. It's always something! :bang:

Jeff, the cable adjuster has nothing to due with the clutch pack. It's just for adjusting the slack out of the clutch lever. You tighten it up till you only have a little gap in the lever. I guess you could tighten it until it pushed on the clutch rod but it's not designed for that. Make sure you pack that thingy with the three balls with fresh grease and ensure there's lots of lub in the cable. Have fun.

Glad you got your cable.