03 Chopper clutch cable, eazy pull ramp.

Energy One

Chong

U-238
Okay ... 03 Chopper. I'm on my third clutch cable now in around 3 years .
That's counting what was on it when I bought it.

After about a hours use my cable stretches. No matter what I've done. Needs adjustment, needs to have the housing adjuster backed out . I've been lubing it with P1 cable lube .

Current cable is maybe a year and light riding and I've used up all the travel in the adjustment.. I just added a shim to the end where it meets the hand control to get some adjustment back. I basically took a lock washer widen the gap to slip over wire cable portion and flattened it .

The two cables were from partsking, not the Barrett cable .. I'd try one of those but usually they are out of stock. I does seem to me when new I'm well past the mid point in the adjustment travel so that's a little frustrating since they keep stretching it seems. And not alot of adjustment travel.

I've inspected the cable and lever end looks in good shape .

Clutch pull pressure seems good . Doesn't feel overly stressed .

What's the history of the easy pull ramp.. I kinda assumed/read it applied more to the later year models like 05 and up ?

I'd be willing to put a easy pull ramp if takes stress of the cable and applies to 03 model year bike. Seriously considering going direct to Barrett for cable .

Thanks for any info you all might have .
 

knothead

Second Chance Customs
Baker drivetrain TBK-56L is for your bike...I have put several in and the clutch pull is crazy soft..

But on 03 models the clutch is pretty easy to pull anyway plus it having the harley controls give it more throw at the lever/hand control for easier clutch adjustment..

04 and up model controls kinda suck really because when they designed them they didnt allow for much travel on the lever which as we know makes the clutch adjustment a little more sensitive...and in traffic the clutch will fade and start to creep thus causing premature wear on the throw out bearing and the clutchs...bad design on 04 and up models in my opinion..

But back to your bike...is your cable close to your exhaust? I'm wondering if thats why the cable is stretching that easy cause it's getting super hot...or is it just hard to pull the lever in period?

My Ridgeback has had one cable put on it in 21 years and it didnt need it then I just done it while I was swapping the transmission..
 

Chong

U-238
Baker drivetrain TBK-56L is for your bike...I have put several in and the clutch pull is crazy soft..

But on 03 models the clutch is pretty easy to pull anyway plus it having the harley controls give it more throw at the lever/hand control for easier clutch adjustment..

04 and up model controls kinda suck really because when they designed them they didnt allow for much travel on the lever which as we know makes the clutch adjustment a little more sensitive...and in traffic the clutch will fade and start to creep thus causing premature wear on the throw out bearing and the clutchs...bad design on 04 and up models in my opinion..

But back to your bike...is your cable close to your exhaust? I'm wondering if thats why the cable is stretching that easy cause it's getting super hot...or is it just hard to pull the lever in period?

My Ridgeback has had one cable put on it in 21 years and it didnt need it then I just done it while I was swapping the transmission..

Thats a good point.. I'll check the exhaust clearance. There are no heat shields on the exhaust.. i know that. The pull is softer then the 04 Bulldog which I've never had a cable issue with.
Thanks !
 

Mr. Wright

Knows some things
Baker drivetrain TBK-56L is for your bike...I have put several in and the clutch pull is crazy soft..

But on 03 models the clutch is pretty easy to pull anyway plus it having the harley controls give it more throw at the lever/hand control for easier clutch adjustment..

04 and up model controls kinda suck really because when they designed them they didnt allow for much travel on the lever which as we know makes the clutch adjustment a little more sensitive...and in traffic the clutch will fade and start to creep thus causing premature wear on the throw out bearing and the clutchs...bad design on 04 and up models in my opinion..

But back to your bike...is your cable close to your exhaust? I'm wondering if thats why the cable is stretching that easy cause it's getting super hot...or is it just hard to pull the lever in period?

My Ridgeback has had one cable put on it in 21 years and it didnt need it then I just done it while I was swapping the transmission..
Hey Knot, is that extra little arm that goes on the ball ramp lever. If that is what you are talking about. I've been running one for years. I'm also still using the original cable.
 

Chong

U-238
Okay think it's solved ! Thanks Knothead !

My big nut was loose !

Yeah big clutch basket nut had backed off. And I'm sure was continuing to loosen and letting the clutch basket and all move away from the clutch rod . Which is why the adjustment keep changing and lever keep getting loose travel.

Once I got the pressure plate off you could move the clutch basket in and out .25" minimum. And basically "0" ft lbs of tourqe on the big nut. Turn by hand.

Red locktite and 80 ft lbs of left hand tourqe now the clutch basket and all don't move (laterally :) ). Cable adjustment is back to about the center of the turn buckle.

Have to get the primary cover back on for a test ride .

Big shout out to Knothead for walking me thru the diagnosis and repair steps !!
Saved my ass again !!
 

knothead

Second Chance Customs
Okay think it's solved ! Thanks Knothead !

My big nut was loose !

Yeah big clutch basket nut had backed off. And I'm sure was continuing to loosen and letting the clutch basket and all move away from the clutch rod . Which is why the adjustment keep changing and lever keep getting loose travel.

Once I got the pressure plate off you could move the clutch basket in and out .25" minimum. And basically "0" ft lbs of tourqe on the big nut. Turn by hand.

Red locktite and 80 ft lbs of left hand tourqe now the clutch basket and all don't move (laterally :) ). Cable adjustment is back to about the center of the turn buckle.

Have to get the primary cover back on for a test ride .

Big shout out to Knothead for walking me thru the diagnosis and repair steps !!
Saved my ass again !!
Glad I was able to help you... phone call answered alot of questions and issues faster... and it was good talking to you as always...hopefully you will be good to go now
 
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