Bottom of Clutch cable, coming out of primary, is oily...
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user_deleted
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1-check primary fluid level to ascertain NOT over-filled. service and owners manual cover checking of same.
2-primary end of clutch cable is a VERY DELICATE threaded barrel with an O-RING affixed to same. the O-ring is the source of your leak.
after performing step #1 take a small open-end wrench and check that the cable is snug at the primary cover end. notice i said SNUG. many an XB owner has destroyed barrel threads, cables, broken off fittings, and other assorted carnage with ham-fisted work in this cable area. if these steps don't resolve the misting of oil from this area the cable will have to be removed and the O-ring replaced.
i'll tell you right up front that completely removing the cable, cleaning and lubing, and replacing the o-ring is not only tedious and challenging for the novice....there is only ONE method of doing it correctly. failure to adhere to same yields nightmare results.
2-primary end of clutch cable is a VERY DELICATE threaded barrel with an O-RING affixed to same. the O-ring is the source of your leak.
after performing step #1 take a small open-end wrench and check that the cable is snug at the primary cover end. notice i said SNUG. many an XB owner has destroyed barrel threads, cables, broken off fittings, and other assorted carnage with ham-fisted work in this cable area. if these steps don't resolve the misting of oil from this area the cable will have to be removed and the O-ring replaced.
i'll tell you right up front that completely removing the cable, cleaning and lubing, and replacing the o-ring is not only tedious and challenging for the novice....there is only ONE method of doing it correctly. failure to adhere to same yields nightmare results.
Wow. Lunatics up early today, I guess i'm not needed:upset:
Haha:angel: He's right again. Lube the o-ring and turn just snug enough to compress the o-ring slightly and No it won't rotate. I actually do it by hand.
Haha:angel: He's right again. Lube the o-ring and turn just snug enough to compress the o-ring slightly and No it won't rotate. I actually do it by hand.
user_deleted
Well-known member
yes....in essence same as sportster. you and your dad will do just fine. allow me to recommend a few things here as clearly you'll have an extra pair of hands for this little project......your ulysses has accrued some miles and age....and my recommendation will improve the clutching/shifting experience:
1-using the manual and your dad's sportster experience.....slide up gaitor exposing adjustment barrel.
2-loosen the 9/16th inch locknut.....now turn the adjustment barrel several turns clockwise till tons of slop at the lever.
3-remove entire cable assembly from lever and perch.
4-remove derby(clutch inspection) cover.....3 torx.....and then remove tension spring and locking-nut exposing the clutch pack adjustment screw.
5-NOW lube the cable...replace the primary end O-ring if required....clean and lube the adjustment barrel area..... lube the lever/perch assembly and eliminate any vertical slop between the perch and lever......reassemble all. NOTE: self-explanatory BUT if you find that you want to replace the primary end cable O-ring at this time you'll also need to remove the cable clamp at the front engine mount and slide cable down thru its fitting in the upper triple clamps.
6-NOW do a full cable and clutch pack screw adjustment as per factory manual specs. if you do NOT know the procedure or confused with the manual ask and i shall walk you thru it.
the above a relatively easy task that enhances both lever feel and shifting qualities.
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user_deleted
Well-known member
My question: is this going to be okay ......yes.
Just a quick question regarding the clutch cable, the Uly has a tin bracket/guide at the clutch leaver. When I tried to totally remove my clutch cable to properly seat it into the bottom of the clutch cover I had to pry off the tin bracket/guide and when I put the bike back together I carefully put it back on. I didn't totally destroy it.
Is it possible to completely remove the clutch cable with the bracket/guide on? I couldn't get the cable to go through the small hole in the the triple clamp.
Is that bracket a replacement part?
thanks
Is it possible to completely remove the clutch cable with the bracket/guide on? I couldn't get the cable to go through the small hole in the the triple clamp.
Is that bracket a replacement part?
thanks
I left mine on. It takes some finagling but it's doable. The biggest thing for me was to make sure the cable was straight below the hole. If it's curved (like it normally is when installed and mounted) then that tin brace binds in that hole. Just make sure it's straight and pull on it from beneath and it should come out.
Putting the new one in is the same boat. Make sure it's going in straight and just push and twist until it pops through. Not sure why they made that such a tight clearance fit.
Not sure if there is a replacement part for that. I doubt it since it comes on the cable.
BTW, where was it leaking? I thought mine was the o-ring (not seated properly) but it was actually leaking around the crimp onto the cable where it comes out of the primary cover. i guess that is common and some people take a silicone heat tape or something similar to that, and wrap that and seal it and it's good. It's not high pressure inside so I could see that being a viable solution. I didn't see that suggestion until after I had mine torn down :upset:
Putting the new one in is the same boat. Make sure it's going in straight and just push and twist until it pops through. Not sure why they made that such a tight clearance fit.
Not sure if there is a replacement part for that. I doubt it since it comes on the cable.
BTW, where was it leaking? I thought mine was the o-ring (not seated properly) but it was actually leaking around the crimp onto the cable where it comes out of the primary cover. i guess that is common and some people take a silicone heat tape or something similar to that, and wrap that and seal it and it's good. It's not high pressure inside so I could see that being a viable solution. I didn't see that suggestion until after I had mine torn down :upset:
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Mine never leaked, I had the side cover off because I dropped the little clutch cable retaining clip into the primary cover. Getting the clutch cable out of the primary cover was easy, getting it back in straight without striping the threads was a different story
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