Clutch cable problem after installing new bars - Road Glide Forums
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post #1 of 17 (permalink) Old 12-04-2012, 04:53 PM Thread Starter
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Clutch cable problem after installing new bars

I just swapped out my Roland Sands 10" bars for a set of Santee 14" bars. While doing so I changed the clutch cable to a 4" longer cable. I already had one lying around from a previous swap that was like new so figured I should instead of getting creative with how I routed it. Everything was straight forward enough until I went to put the clutch lever together. There is almost no free play in the cable, maybe 1/16" but thats it. And the cable is adjusted all the way in.
the bike has about 800 miles on it and I have not adjusted the clutch pack yet but I'm worried that I don't have enough free play to adjust it. I pulled it apart twice now to make sure nothing is binding and everything looks good. Any ideas?
Can it just be an adjustment to the clutch pack even though everything was fine when I pulled the stock cable off.

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post #2 of 17 (permalink) Old 12-04-2012, 04:57 PM
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if you pull your cable by the lever is it set per the service manual?

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post #3 of 17 (permalink) Old 12-04-2012, 04:59 PM Thread Starter
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I don't have enough free play to put the lever back together. There is about 1/16 of an inch of cable between the loop and the cable end. can't get enough to even put the lever back together.

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post #4 of 17 (permalink) Old 12-04-2012, 05:04 PM
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im sure you have the adjustment and jam nut as loose as it wil go. Turn the handles all they way to the right and se how far your away. You might need to get a longer one. The manfacture of the bars or aftermarket vendor that sells them should know the correct length needed.

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post #5 of 17 (permalink) Old 12-04-2012, 05:16 PM Thread Starter
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Actually the overall length of the cable is fine. The problem is even with the adjustment nut turned all the way in there is no free play to put the lever back together. Not sure why.

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post #6 of 17 (permalink) Old 12-04-2012, 05:31 PM
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That is strange, I just read through the ser. man for mine and the only adjustments are the adjustment nut and jam nut. Loosen up the jam nut and screw the adjuster towards the jamnut.

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post #7 of 17 (permalink) Old 12-04-2012, 05:37 PM Thread Starter
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Yup this doesn't make any sense. I can't believe that this is due to the clutch pack.

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post #8 of 17 (permalink) Old 12-04-2012, 05:41 PM
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Do you have any play with the release housing on the trans taken off? Possibly when you replaced the clutch cable on that end something didn't go back together correctly.

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post #9 of 17 (permalink) Old 12-04-2012, 05:52 PM Thread Starter
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Yes. Every time I take it off there is about 1 1/2" or more of play. However that is with the arm on the ramp pushed towards the edge of the trans cover. When you center the ramp arm you lose about half of that. It's almost like the cable housing is too long compared to the cable. I'm at a loss. Might be time to get a different cable.

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post #10 of 17 (permalink) Old 12-04-2012, 06:08 PM
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the inner ramp should be in a 11 or 1 oclock not 12 oclock

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