Clutch Cable Install

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I am glad to hear this bitter, very surprised though. Tyler's a good guy. Lets hope the second time around goes a little better for you.
 
Well, now I have the new cable and it is installed....and I didn't break anything, YET. But now I am having trouble adjusting the clutch so that the bike is moving freely with when the lever is pulled. Anyone done this recently? I am such a stupid newb with this stuff, sorry!

I have adjusted the cable length, and the ramp assembly...not really sure what I need to do. thanks for the help in advance.
 
Getting it just right can take some time adjusting and readjusting.

Get the rear tire off the ground, loosen the jamnut on the cable adjuster. Turn the adjuster until there is a lot of freeplay in the clutch lever. Then remove the clutch inspection cover and also remove the spring and lockplate. Then turn the adjusting screw counterclockwise until it bottoms out and then rotate clockwise. This is the step that you may have to repeat to get it right. The manual says to rotate it 1/4 turn, but I had to turn mine about 1.5 turns to get it right. Put it back together and pull the clutch lever 3 times, then adjust the cable that adjusts the lever freeplay.
 
thanks to all that have helped me in this project. Finally got it together and working properly. May have to adjust the cable in the future. Today, I actually got to ride for about an hour or so. New cable is nice and pulls a lot easier then before. I have one helluva Buell smile today!! :D
 
A tech told me that the amount of free play needed is the width of a nickel. On the clutch lever, you want to be able to put a nickel in the space. It took me 3 adjustments to get it right.

1832_20090418103015_L.jpg
 
That looks great. Is the clutch closer now to your hand then the stock? I need to get an ajustable clutch lever. Is that a Shorty?
 
Hope you guys don't mind the thread resurrection...

Thanks to everyone in this thread.

I managed to get my clutch cable swapped out last weekend on my '03 XB9R.

It was a slow process -- mostly because I don't know what the hell I'm doing. I used this thread and the owners manual as my main references.

I made the mistake of dropping that coupler thing into the primary! Tried the magnet on a string, but that didn't work. I ended up having to remove the primary cover.

But it all worked out in the end. My bike is back running again! :)
 
I had the same problems with not being able to connect the cable behind the inspection plate... I lossened the adjustment screw till it all came apart.. got the cable on fine and everything back together but cannot get the bike to move freely when pulling the clutch... Is it possible I messed something up by pulling the whole ramp assembly off to get the cable on? Or do I need to just keep adjusting 1/4 clockwise till it moves Ok? Any help would be great thanks...
 
Did you do the "pull clutch lever 3 times, THEN adjust it" step?
As mentioned back on page 1 in the post by 03Firebolt9R dated 18 Apr 2009 @ 11:08 ?
 
Yes, I let the cable all the way out... Turn adjustment screw counter clockwise till stopped. Backed it off 1/4 turn... Replaced cover, took slack out , pulled clutch lever , the adjusted cable again till 1/8th of slack... Bike will not roll freely with clutch pulled.... Do I keep adjusting the screw clockwise and repeating? My worry is that I had to run the adjustment screw all the way in and remove the assembly the cable hooks to to get the cable on... It went back together easy but could I have done something wrong here?
 
Have you tried starting the bike, and then kicking it into gear with the clutch pulled in? When they are cold its never easy to move in gear with clutch pulled in. Wet clutches have a lot of drag.
 
No I have not tried that for fear it would hurt something kicking it in gear without the clutch... I did start it but did not put it in gear. I'll try that when I get a chance to mess with it. Also what fluid do I use and how much to refill? I had to drain it completely because I lost the cable holder in the case.
 
You wont hurt it by putting it in gear. If it truly isnt working right it will just stall kicking it in from an idle and lurch forward a bit. You might hurt it starting it with no fluid.

Its uses 1 quart of any of the below
20w-50 v twin engine oil
HD formula+
i use maxima mtl 85wt transmission oil that is jaso ma rated for wet clutches
 
Super old post, but my Uly came with adjustable levers. My concern is that if you adjust them closer to the grip, wouldn't that give you less travel and possibly not disengage the clutch fully or might use up some of your brake lever's travel and thus prohibit you from fully utilizing your front brakes? I leave mine fully extended for this reason (and I have big hands)
 
I dropped that damn retaining clip for the clutch cable into the primary case... Off came off the primary cover to retrieve the clip. Adjustment of the clutch was fine. Mine too did lock up because of the drag of the clutch plates, when I had the clutch cable adjusted properly. My issue now is getting the primary chain adjusted correctly :-/
 

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