Clutch Cable Broke- twice! Help!

[surferdude]

Ok what are the steps to lube the rod, ball and ramp. Also how do you keep the cable tension tight? I adjust the cable tension but the nut that holds the housing just doesn't keep the housing still ... so the vibration from riding loosens the tension and then I have a lot of play in the cable ... any ideas?
thanks

 

[lee]

this has a picture of the pushrod adjuster - the allen key is in the end of the pushrod - pull that out and get as much grease in there as you can and put it back in - to get to the ball and ramp mech, remove the pulley cover where the clutch cable if fitted to and it is on the inside of the cover - unbolt it and grease it up - 3 ball bearings inside 3 grooves

http://www.bigdogbiker.com/forums/how/2025-how-adjust-your-clutch.html

 

[556K9]

UPDATE- My dealer replaced this cable, and upon reinstallation everything looks good. I really think I just had a defective cable here, although this time around the lever was not hard to pull like last time. Everything looked good with the ball and ramp, so maybe the first time around I had something misadjusted.

I want to give a big thank you to everyone who helped out here. I am very glad that my recently-out-of-warranty K-9 does not need open heart surgery! I took it out for a little ride just now and everything seems great!

 

[lee]

good news

 

[05Bulldog]

In ref to the bolt lengths...they're all the same. Took mine apart cause I thought I broke ANOTHER clutch cable but found the end of the cable housing (top) did not seat completely in the hand control after the dealer adjusted the clutch. Problem was the shifter arm (on tranny) bolt had come loose and would not shift into first. Thought I had big problems. Phew!

 

[TheRickster]

Cltuch Cable Failure

Just had my 5K service on the 2006 K9. A few days later on a Sunday evening I rode the bike for about 8 miles and the original clutch cable snapped at the transmission end. I was just taking off from a light at a busy intersection. I was able to pull over and wait for a flatbed to pick it up and bring it back to my house. I had an easy pull clutch installed back in May so I guess it would have snapped sooner if I had not done that. I could not find a clutch cable in town so the next day I loaded a borrowed trailer and brought the bike back down to Joe Harrison Motorsports in San Antonio, 90 miles from Austin. They were able to get me in the same day I called because they had very little service business.
Before I drove down, I verified that they had a cable, they said they had only one in stock that would work. Even with the extended warranty still intact, the clutch cable was not covered.
Upon arriving they told me that the cable they had was from a Ridgeback and that it was a few inches longer but would work. I was told the clutch cable from Big Dog for the K9 was backordered going on 2 ½ months now.
The cable cost was $72.00 and labor was $119.00. They knocked off 15% off the labor for my trouble. Ron is the Big Dog expert mechanic at the dealership. He said that back in 2005/2006 they had cable design issues but have since corrected them. He said that I should not have to worry with the new design cable and the easy pull clutch installed. I plan on getting an extra cable once they become available again.

Rick :flag:

 

[chaingunner]

Just had my 5K service on the 2006 K9. A few days later on a Sunday evening I rode the bike for about 8 miles and the original clutch cable snapped at the transmission end. I was just taking off from a light at a busy intersection. I was able to pull over and wait for a flatbed to pick it up and bring it back to my house. I had an easy pull clutch installed back in May so I guess it would have snapped sooner if I had not done that. I could not find a clutch cable in town so the next day I loaded a borrowed trailer and brought the bike back down to Joe Harrison Motorsports in San Antonio, 90 miles from Austin. They were able to get me in the same day I called because they had very little service business.
Before I drove down, I verified that they had a cable, they said they had only one in stock that would work. Even with the extended warranty still intact, the clutch cable was not covered.
Upon arriving they told me that the cable they had was from a Ridgeback and that it was a few inches longer but would work. I was told the clutch cable from Big Dog for the K9 was backordered going on 2 ½ months now.
The cable cost was $72.00 and labor was $119.00. They knocked off 15% off the labor for my trouble. Ron is the Big Dog expert mechanic at the dealership. He said that back in 2005/2006 they had cable design issues but have since corrected them. He said that I should not have to worry with the new design cable and the easy pull clutch installed. I plan on getting an extra cable once they become available again.

Rick :flag:

Do like a lot of us did and contact Barnett, they will fix the old one, you pay shipping one way, the rest they pick up. than at least you'll have a spare. There is even a "how to" so you can DIY.

 

[T.Byrd]

I've purchased a 08 ball and ramp for mine they say they really make a big differance on the pull. You might try this.

 

[TCALZ06]

I've purchased a 08 ball and ramp for mine they say they really make a big differance on the pull. You might try this.

Let us know if this helps when you install this.

 

[TCALZ06]

One more thing I noticed when I installed the cable today. I don't know if it's normal because I've never done one of these before. When I was reinstalling the side cover, it was just shy of going flush with the side of the case. I started the three bolts and ran them down slowly and equally and everything closed up nicely. I did not have to force any of the bolts to make this happen, but for some reason I could not get the cover flush with the case by hand. I was about an 1/8" away from flush until I installed the bolts. Anything wrong here?]

You should run a tap through all three holes. also I believe my manual says locktight on those bolts