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Sketchy
Posted on Saturday, January 09, 2010 - 08:31 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Man, I purchased my 2nd Buell about 2 months ago and not even 700 miles later I noticed the clutch cable leaking at the bottom. It seemed to be leaking right below the silver bolt underneath the plastic sheath. I took it to Guam Harley-Davidson (no joke) and they replaced it with a 2009 XB12R cable only to have the same thing happen. I told them "hell, try a 2007 XB9R cable" since I own a 2007 XB9R and the cable has never leaked. That leaked too and now I have a 2009 XB12R with a consistently leaky clutch cable and mechanics that look to me for advice. I need help. Anyone got anything for me?
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Froggy
Posted on Saturday, January 09, 2010 - 09:46 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

The clutch cable would be the same both years. Did they use the new o-ring that comes on the cable? It is also possible the primary cover is defective.
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Sketchy
Posted on Saturday, January 09, 2010 - 10:18 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I didn't know there was a new O-Ring that was included with the cable. I had someone look at the cable and they seemed to think there was a inner-stopper missing from keeping the fluid in the cable. I am so stumped and dont think the service I am getting is top notch as this dealership just gained rights to service Buells b/c of my company Military HD/Buell Sales. We even had to pay for half of their tools for the Buells and still these guys have no idea how to troubleshoot a Buell. Help People. Froggy, does the O-Ring come with every new clutch cable?
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Froggy
Posted on Saturday, January 09, 2010 - 10:24 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

It should be on it already. I recall some old posts were people got cables without the o-ring for some reason.
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Bobbuell1961
Posted on Saturday, January 09, 2010 - 11:54 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sketchy, the o ring should come w the cable, the problem is usually at the crimp,if great care is not taken and you flex the cable when installing you will get a leak,
It is a common problem w HD/Buell cables
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Rays
Posted on Sunday, January 10, 2010 - 12:18 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I have now purchased two new clutch cables for my '06 Uly and neither of them have had the O-ring included.

When I used the first one I noticed that here was no reference to this O-ring in the parts manual so I re-used the original one with a light smear of silicon sealer - that has sealed perfectly.

This is the clutch end of the cable and an example O-ring.


This is where it is positioned when installed.


This end should be installed VERY carefully and tightened just enough to seal the O-ring.

The advice from Al Lighton in this post in the KV should be taken very seriously as there have been a lot of tears shed over this particular piece of hardware.

http://www.badweatherbikers.com/buell/messages/384 2/410715.html?1225990635
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Bobbuell1961
Posted on Sunday, January 10, 2010 - 12:34 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Ray, Courts reply is a little strange
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Wolfridgerider
Posted on Sunday, January 10, 2010 - 01:24 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I just replaced the clutch cable on both my bike and neither one came with a O ring.... bummer.

Check the breather line on the primary. It may be pinched.
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Ducbsa
Posted on Sunday, January 10, 2010 - 07:58 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

When installing a cable, try screwing it in while keeping it as straight as possible, then feeding it up through the front of the motor and to the handlebars.
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Spatten1
Posted on Monday, January 11, 2010 - 10:25 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Mine has always weeped. It's not really leaking, just marking it's territory.

There is a reason that modern bike's clutch cables engage a shaft at the top of the case cover, rather than going into the case cover, at the bottom of the cover!

It's an old design and not perfect, so I just let mine weep a little, doesn't hurt anything.
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Sketchy
Posted on Monday, January 11, 2010 - 10:20 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

thanks guys for all the help, you are more reliable than my dealership!
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Rays
Posted on Wednesday, January 13, 2010 - 05:29 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sketchy, I just got my 2009 Parts Catalog today and it shows the O-ring (but not in the X and XT diagrams) - the part number is 11179.
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Fahren
Posted on Wednesday, January 13, 2010 - 11:46 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

the part number is 11179
an o-ring, no doubt available as a two-week special order item from your HD dealer, for the mere cost of $27.99 LOL
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Froggy
Posted on Wednesday, January 13, 2010 - 02:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Retail price is 95 cents, and it should be in stock at most dealers as its a common part on the clutch cables of many HD models.
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Stewsdad
Posted on Friday, May 13, 2011 - 05:52 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Does anyone know the actual size for the o'ring? Mine is weeping, not marking it territory but I am an hour from the nearest dealer and the o'ring should be an easy pick up at the hardware store.
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