Clutch Cable Inspection Case - Help with WTF found bearings rolling loose in case.

Mojopojo

Member
I ride a 2004 BD Chopper. About 2 weeks ago the clutch cable froze up on me, and after making adjustments it seemed to be fine. Then within a week while riding the cluch control went slack. I thought I snapped the cable so I ordered a new one from BD and got the case gasket I needed from Baker.

When we opened the clutch cable case we found that not only had the cable NOT snapped, but that everything appeared to be in order except for the discovery of what appeared to be a lock-washer and 8 flint-sized needle-bearings (** see 1st attached picture of needle bearings and washer found in caseing).

All of the needle bearings had been trapped in the inspection case's inner housing (*see picture 2nd pic with yellow circle indicating where we found the needle bearings)

I can not find an exploded view of the assembly. I don't know where these came from or what came apart in my clutch or why.

Also, we only found 8 needle bearings. And if they coincide with the spacings of this washer, then I would have expected to find 9. I do not want a loose needle bearing rolling around in my transmission - though we can not rule out that it may have been flushed out with the fluid.

Anyone shed some much needed light on this? I have a 2004 Chopper manual but it doesn't have an exploded view of this assembly.

Thanks
 

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