Clutch Cable

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Avanti

Member
My cable on my 2008 MUTT, 10K miles just broke rite at the eyelet end. Got it all out but have a few questions. first is it normal for that to break so soon with only 10k miles? second who has the best price on a new cable specificly for my bike, no cuttin solder ect needed? Third is when it al back together how do u adjust the clutch at the engine end. It there a web site that i can go to and down load how to do that?
thanks
nick
 
Dezertrider37v

Dezertrider37v

Member
Nick,
Let me see if i can answer your questions;
Is it normal to break with 10k...Mine broke the first time around 4k
Best price....Call Amy at Stokers of Dallas or try J&P cycles either way its about $68.00
Adjusting the ball and ramp......In my opinion youu shoudnt have to change that adjustment. I have checked mine both times i replaced my clutch cable and it was fine.
I see that EZDOG hooked you up with a shop manual link too! He deserves some rep power for that!
 
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woodbutcher

Mr. Old Fart member #145
Staff member
Barnett Performance Products | this is the manufacturer of the original cable. it is not a problem with the cable, it is a problem with BDM's design of the mechanism which activates the clutch rod. buy from Barnett and send them the broken one and they will repair for free so you will have a spare for the next time. Barnett stands behind it's products.
 
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Avanti

Member
VERY GOOD INFO andthanks for getting it to me. I havealready taken the cable out, but printedthis out anyway. My pipeswere in the way, but by taking thejamnut off I was able to push the Clutch Rod IN toward the left side of the bike. By doing that I was able to pull the cover off.It is alreadyapart andnow Iam looking for the exact replacement cable,where? andis there such a thing as a heavy duty one? When Iput it al lback together iswheni have to figureout how to"set up" the clutch rod?? Any info on that? Also wherecan I go tofind info simailir to whatu gave me? BIG BOTTOM LINE !!!THANKS!!!
 
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woodbutcher

Mr. Old Fart member #145
Staff member
Avanti said:
what is wrongwith the way BD did the clutch rod and can anything bedone to improve it?
thanks
Click to expand...

nothing really wrong, it just has an extreme amount of pull on it and it tends to snap cable ends. something that helps is to make sure you keep the cable lubed by spraying a good cable lube into the cable housing. it's just another part of regular maintenance for your pup. :cheers:
 
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VegasBulldog06

New Member
The clutch cable is a design issue, replaced 2 and have 5k on a 06 Bulldog. adjusting the clutch and pushrod all the way out to activate in the 1st 1" to 1.5" lever pull is the only way to keep the cable to ferrule angle so that it wont rub on the clutch actuator housing. I had lots of adjustment left in my cable so twice i have machined a "barrel" for the end of the clutch cable that fits into the clutch actutor housing ferrel, then silver soldered to clutch cabel. see attachment. First Post, hope attachment and post is proper,,
 

Attachments

Fibersnake

Fibersnake

Banjo Playing PsychoBilly
They wear out occasionally. Some will go many mile other not so much. Depends on how well it is maintained and how the operator uses it.

As mentioned, give Amy a call at Srokers and she will get you set up with the proper cable.

Make sure to properly lube the interior of the cable housing well, and do such as part of a normal maintenance routine. Also keep the ramp and accuator well greased. I try to get both done during ever other oil change (about 5k or so).

When you do grease the ramp, good time to inspect the cable end to check for fray or damage. Lube the cable is easy if you get the lube with the neddle applicator. I use a graphit lube myself.

Still first cable went at about 20K, second seems to be holding up good.

Also as mentioned send the broken back to Barnett and they will repair and you will have a second for spare and not bad item to throw in bags on long trips.
 
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Avanti

Member
Reusing the old cable is a good idea except mine broke at the leverend, theEyelet snapped in half, andy fix for that?
thanks
 
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Avanti

Member
the "ramp" is insidethe coverwhere the3 balls are rite. If so it seems like a bighassle to grease as u haveto takeeverything apart just like u do to replacethe cable, unless there is a grease fitting and i did not see one??
thanks
 
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woodbutcher

Mr. Old Fart member #145
Staff member
the ramp probably only needs to be re-greased about every 20K, not every time you change the oil. or when the cable breaks :roll::roll::2thumbs:
 
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Avanti

Member
called barnett this morning u guys were rite very nice people to deal with. They had no specs onb the cable so they want me to send them mine, will sell me a newonne andfix mine for freeYEAA and THANKS GUYS!!
 
Fibersnake

Fibersnake

Banjo Playing PsychoBilly
woodbutcher said:
the ramp probably only needs to be re-greased about every 20K, not every time you change the oil. or when the cable breaks :roll::roll::2thumbs:
Click to expand...
I tend to grease mine about every other chagne, it only take about 15-20 min to pull it, check the cable, grease and reassemble, lube the clutch rod and adjust.

After having one go out on the road, feel better to check it every so often.

Probably more than I need, but it works for me.
 
oldmutt

oldmutt

Active Member
I am with you Fiber. It takes less then 30 minutes and after the cable lube and grease the pull feels so nice. It makes a major difference.
 
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