Replacing the clutch cable is relatively simple, but can be time-consuming
Based on Harley-Davidson’s powerful V-twin motors, Buell’s line of sport motorcycles are built to be ridden hard. However, the motorcycle’s steel clutch cable can stretch or snap after many long and fast rides. Replacing a worn-out clutch cable is a fairly simple task, but can be time-consuming since the cable is connected to the transmission’s internal clutch mechanism. This requires you to open the motor’s primary housing to access and remove the cable. Be sure to take your time to avoid making mistakes that could potentially damage your motorcycle.
Clutch Cable Removal
1. Remove the lower chin fairing from the motorcycle. Using a Torx driver, remove the Torx-head bolts and washers from the center and side panels of the chin fairing. Lower the chin fairing to the ground and pull it away from the motorcycle.
2. Pull the cable out of the cable holder under the steering head. Using a Torx driver, remove the Torx-head bolts that secure the tie bar to the V-shaped bracket on the bottom front of the motor. Remove the tie bar and the clutch cable’s P-clamp from the V-shaped bracket.
3. Follow the clutch cable from the motor up to the handlebars. Using a razor blade, cut the nylon cable strap that secures the clutch cable to the voltage regulator’s wiring harness.
4. Push the rubber clutch cable’s adjuster boot, located at the midpoint of the cable, up and away from the cable adjuster. Loosen the cable adjuster‘s lock nut with a 10 mm wrench. Twist the adjuster clockwise until it is seated against the cable end to loosen the cable completely.
5. Pull the clutch cable out of the clutch perch, sliding the inner steel cable through the groove cut into the perch. Pull the cable’s end barrel out of the clutch lever. Pull the cable away from the upper fork clamp and handlebars.
6. Using a socket wrench, remove the flange bolt that secures the shift lever to the motor’s primary cover. Pull the shift lever away from the motor. Remove the clutch-inspection cover from the primary cover, using a Torx driver to unscrew all three Torx-head bolts.
7. Pull the spring off the hexagonal adjusting screw. Using a socket wrench, twist the adjusting screw clockwise to loosen the ramp hook that secures the clutch cable to the clutch mechanism. Pull the cable’s barrel end out of the clutch mechanism. Unscrew the outer clutch cable from the primary housing and pull the cable away from the motorcycle.
Clutch Cable Installation
8. Prepare the new cable. Push the rubber clutch cable‘s adjuster boot, located at the midpoint of the cable, up and away from the cable adjuster. Loosen the cable adjuster’s lock nut with a 10 mm wrench. Twist the adjuster clockwise until it is seated against the cable end to loosen the cable completely.
9. Slip a new cable O-ring over the threaded end of the clutch cable. Screw the threaded end of the clutch cable into the primary cover, pushing the inner cable and barrel end into the primary housing. Slip the barrel end into the notch of the clutch mechanism‘s cable coupling. Use a socket wrench to twist the adjusting screw counterclockwise to tighten the ramp hook over the clutch mechanism. Slip the spring over the adjusting screw. Reinstall the clutch-inspection cover, using a Torx driver to insert and tighten all three Torx-head bolts.
10. Route the clutch cable up from the motor to the handlebars. Insert the barrel end of the cable into the clutch lever’s catch and pull the inner cable through the groove cut into the lever. Pull the inner cable through the groove cut into the clutch-lever perch.
11. Place the P-clamp over the clutch cable and reattach the P-clamp and tie bar to the V-shaped bracket on the bottom front of the motor, using a Torx driver to insert and tighten the bolts. Slip the upper portion of the clutch cable into the cable holder under the steering head. Secure the cable to the voltage regulator’s wiring harness with a nylon cable tie.
12. Pull the clutch lever in three times to set the clutch mechanism’s ramp, then release the clutch lever completely. Pull the clutch cable away from the clutch perch and hold it in position. Tighten the clutch cable by twisting the cable adjuster counterclockwise until there is 1/16- to 1/8-inch of excess inner cable showing between the cable and the clutch-lever perch. Tighten the cable adjuster’s lock nut with a 10 mm wrench and slide the rubber boot over the adjuster.
13. Slide the lower chin fairing under the motorcycle. Lift the chin fairing into position beneath the motor. Insert and tighten the Torx-head bolts and washers into the side and front panels of the chin fairing using a Torx driver.