| Author | Message | ||
     Mr2shim |
So I was just installing my clutch cable after the original cable broke at the lever. Anyways, without warning the threads broke off into the primary like melted butter. (no I wasn't over tightening it) So now, I'm going to have to A: Buy another cable B: Buy a new primary cover. Fun fun....  Anyone have a spare primary cover? (Message edited by mr2shim on April 04, 2008) | ||
| Tom_k |
Is the threaded end of the cable still in the primary cover, or did it destroy the threads in the primary cover? If you are worried because the broken end is still in there, get an E-Z out and try to screw the broken piece back out. It the threads in the primary cover got damaged you should be able to: clean them up with a tap if they aren't too bad, or have a Helicoil inserted by yourself or a competent machine shop. TK | ||
| Mr2shim |
I don't think an ez out would work. At this point I'm just trying to source another cover. | ||
| Ratbuell |
I've had the same thing happen. If you weren't over-tightening it the broken piece isn't in there all that tightly, you should be able to get it out with no problem. I got mine out with nothing more than a phillips head screwdriver shoved up against the broken tube nice and hard so it "bit" into the end. Got it out enough to put hands on, and undid it by hand from there. It's not the tightening pressure that breaks the end off, it's pulling it to one side or the other. The shoulder of the fitting is the weak point. Now, the first thing I do when I replace a clutch cable is make that attachment - with the cable detached from the rest of the bike and flopping around, it's easier not to side-load it. Once you're threaded into the primary, then attach the end of the cable to the clutch ramp and adjust, then route it up to the handlebars and attach/adjust up there. | ||
| Spatten1 |
I hate that design. | ||
| Mr2shim |
Ratbuell. I'll try that now. It's good to see I'm no the only one that's suffered from a crap design. | ||
| Mr2shim |
Ratbuell. That worked like a charm. Thanks a billion. But I still have to buy another cable. H-D claims that it would only have a warranty if it was dealer installed. | ||
| Ccryder |
Three things you need to do to keep this from happening again: 1) Like RatBuell said: the side loads are he!! on these fittings. 2) Lube the cable end where it attaches to the lever. 3) Lube the cable. I have one of those cable lube devices that attach to the lever end of the cable and you can squirt in your lube of choice.  There are a couple of suppliers like: http://store.uncommonmotorcycles.com/cableluber.html The one with only one knurled knob won't fit around the clutch cable. Neil S. | ||
| Skinstains |
If you take the primary cover off you may have the end of the fitting sticking out on the inside. Then just spin it through. If not it should come out easy from the outside with an easy-out if it wasn't tight fitting. Buying a new primary cover is $220.00 new. If you go that route, and your primary is black, I'll give you $50.00 for it. Good luck. | ||
| Mr2shim |
I got it out and ordered another cable.  | ||
| Spatten1 |
Once again, Harley should look at the way the rest of the world does it and give some thought as to why. External clutch cables make much more sense. Water doesn't get in, and oil doesn't leak out. | ||
| Pwnzor |
Try unplugging your stator wires behind the secondary drive sprocket cover some time. See if primary fluid flows out of the plug like mine does! | ||
| Al_lighton |
Every now and again, I suspect that a bad cable end ferrule is made. But more often than not, it is the way that it is installed that causes it to break. There is ONE proper way to put that cable in. With the cable unrouted and laid out in a straight line in front of that fitting, you thread it in and then just gently snug it down. There is no reason to put big torque on it, it has an O ring seal and it isn't going to spin loose on it's own once installed. Once installed and snugged down, THEN route it up to the lever from the bottom. It's best done with the chin cowl removed. If you route it from the top and then thread it in, you will inevitably put reverse bending in the ferrule as it is threaded in and then it snaps off with very little force once you try to snug it. Al | ||
| Irideabuell |
I installed a new clutch cable a few months ago and I believe the service manual clearly states not to twist the cable as it's threaded in the primary like Al mentions above. Mine works fine and was very easy to install. |
