| Author | Message | ||
     Wbrisett |
So, yesterday evening I decided to finally put on the new clutch cable and mount for the cable (my old cable mount broke and melted the sheathing on the cable). So, I take off the old cable, all goes well. It's getting dark, but I proceed anyhow. I get the top of the cable done, routing done, then proceed to screw it into the clutch housing. I think I'm just about there, but couldn't visually tell. I turn my wrench another 1/4 turn and SNAP... I officially belong to the too much torque on the clutch cable club... Son-of-a-gun...  It's too late and dark to see the real damage until this morning. Looks like I did a job on it. I can ONLY hope that I can get my Grabbit's to reverse that puppy out of there. Anybody else got ideas for getting the threaded cable end out of the clutch housing? Wayne | ||
| Crusty |
Pull the primary cover. Then you can get at the broken end and turn it so it backs out. | ||
| Mark_weiss |
Cut the cable near the cover, so that you can push the end in. The threaded part will unscrew pretty easily. Next cable, do the bottom first. Hardly more than finger tight this time. | ||
| Ourdee |
That's 3 20s down the drain. Sorry to hear it. I just barely snug it. Just a hair of a turn. It has an o-ring and wont loosen itself. | ||
| Al_lighton |
NEVER, EVER, route the clutch cable prior to threading it into the housing. ALWAYS lay it out in front of the primary, and if you have a helper, support it as axially as possible while threading it into the hole, rotating the entire cable assy. Once it touches down on a NEW o-ring, just a tiny bit more torque and it's done. Route it up to the top after it is in place, protecting the ferrule from as much side bending as possible. Once properly installed, they rarely break without some additional trauma. The material that the ferrule that threads into the case is not very strong, and the hard 90 degree corner at the end of the threads is a large stress riser. The hole through the center is a tad larger than it needs to be. All this, plus even the littlest amount of reverse bending while threading it in, is a recipe for a low cycle fatigue failure there. I'd requested that Buell make a design change on that, but I'm not sure if my request ever made it to the right ears. I sure wish they had, I have customers breaking them all the time, and the best I can do is to sell them another one at cost. HD won't warranty them if they don't install them, and I can't warranty them, I don't make enough on them to be giving them away when they get broken. I've had a few customers get pretty pissed off at me because I won't give them a new one, but there isn't anything I can do about it. *I* don't build them, and *I* don't get them for free either. As far as getting the old one out, it's pretty trivial. Cut the cable, remove it,wedge a torx bit of the appropriate size into the hole and she'll back right out. Al | ||
| Teeps |
Al, Maybe American Sport Bike could petition Barnett to make cables to "your spec" and end this cable of shame... The above instructions/advice are appreciated. P.S. I only turn the cable ferrule 1 flat or less once I feel it has bottomed on the case. | ||
| Wbrisett |
As usual, Al provides a wealth of information. I knew better than to do what I did last night, oh well live and learn and Ourdee your right, I might as well have just taken the $60 and lit a match to it. Now, I have to see if I can get a new cable in time to do my TX, NM, CO, AZ, UT loop on the Uly (I was planning on leaving in a just over a week). Wayne | ||
| Cyclonedon |
I did the same thing. I busted mine when I went to replace the first one so I had the dealer do the next one. They are very easy to break. | ||
| Court |
Al: I love you Man . . . . Court (a long standing idiot who relies on folks like you to keep me out of trouble) | ||
| Hooper |
Great timing! I'm about to install my new cable (the old one was down to about 2 strands). I ALWAYS read threads with names like this one.  | ||
| Wbrisett |
The good news! My local dealer found one not too far away and so they should have it tomorrow!  Which means, the Uly will definitely be with me on my multi-state tour of the desert SW. Hooper... The question is, why is it, we'll post stuff like this and admit we screwed up, but getting us to stop and ask directions takes an act of Congress!  Wayne | ||
| Hughlysses |
I officially belong to the too much torque on the clutch cable club... Son-of-a-gun... This must be a pretty big club by now; I'm a member too. They wouldn't go too far wrong if they just removed the hex on that cable completely so you could only screw it in finger-tight. | ||
| Teeps |
Wbrisett Posted on Tuesday, August 09, 2011 - The question is, why is it, we'll post stuff like this and admit we screwed up, but getting us to stop and ask directions takes an act of Congress! Same reason "we" don't ask for directions, when traveling. | ||
| Froggy |
I think it is a sign you should of got the hydraulic conversion. | ||
| Zac4mac |
Glad to see Al's tutorial. I have given the same story to a dozen or so Harley riders who come in thinking I sold them a defective cable. Sportster, Buell or Big Twin, it's all the same. Hydraulic clutch is the shizzz. Z |
