Help with finishing clutch cable installation

[nwguy]

I'm replacing the clutch cable on a 2007 xb9sx. How do you remove the clutch cable end from the bracket inside the primary housing? See picture below. The space between the red arrows isn't deep enough to slide the cable end back enough to release it. There's plenty of slack in the cable as I've detached the cable from the lever and loosened the sleeve adjuster mid-cable all the way, and have turned the clutch plate adjuster screw clockwise to loosen it. I just can't pull the cable end free of the little bracket there. Help!

 

[Livers]

Pull the ramp assembly out of the cover and rotate the coupling and it should come loose from ramp hook. You have to run the adjuster screw all the way in to release the thing.

Make any sense?

Edited to say be careful and don't drop the coupler down inside.

 

[TooFst]

I was an automobile mechenic for years... Still in the industry and still do ALOT of side jobs. My cluch cable broke and that's the only time my bike has ever been in the shop. Just plain ole' could not get the new cable in(at the same spot your pointing at). Sorry for the rant. Wish I could help more. My local Harley shop charged me 40$ cuz I already had it tore down to that point. Good luck. Josh

 

[nwguy]

I read the manual, you have to remove the clutch adjusting plate. It's easy. Unfortunately I now find that I have the wrong clutch cable. The threaded sleeve that threads into the primary housing is ever so slightly larger in diameter than mine, so it won't thread in. Now I see the part numbers are different. Mine is:
38613-03 A

The cable I got from Iron Machine is:
38613-03 C
which they list as the oem part (NOT).

 

[nwguy]

And yet more...

I called Iron Machine. They said that the trailing letter on the part number means nothing. It's just a newer part that superseded the old. He said the screw machine that manufactured the part could have been off and the part may be defective. I actually cleaned up the threads at the end with a thread file (they're 24 tpi), so it's not that. My micrometer measured the o.d. as .015" bigger on the new part than the old. The Iron Machine guy suggested I try threading a fine thread 5/16" nut on both. Also suggested that I could chase the threads on the new cable with a 5/16" die, but to be careful of breaking the cable end. I'm off to the hardware store now to buy a nut. Sheesh.

 

[Livers]

That "C" should just be a later revision of that cable. Find yourself a 5/16-24 nut and see if it threads on both.

 

[nwguy]

End of saga:

Went to the hardware store with my cables and a 5/15x24tpi nut threaded on fine to both cables. Bought a 5/16x24 bolt to test-thread into the primary cover. Went home, bolt threaded in fine. Putzed with the cable more and it threaded in fine.