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HARLEY DAVIDSON STAINLESS STEEL BRAIDED CLUTCH CABLE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame

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HARLEY DAVIDSON DIAMONDBACK "LE" CHROME SERIES CLUTCH CABLE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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CLUTCH CABLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery or main fuse following the instructions in the appropriate Service manual. 2. When performing cable disassembly procedures, make careful notes as to the existing cable routing and existing cable strap locations. New straps can be installed in the same locations. 3. Remove the clutch cable following the instructions in the appropriate Service Manual. 4. If installing different handlebars, install them now (refer to the appropriate handlebar instruction sheet) and measure the change in distance that will be required from the end of the cable housing to the clutch lever. Install proper length clutch cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00448b) 5. Compare the additional required length to the cable provided in your kit. If the cable is more than two inches (50.8 mm) longer or more than one inch (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. CLUTCH CABLE INSTALLATION Sportster and Softail Models Do not over-tighten clutch cable threaded end fitting. Use recommended torque values. Damage to threaded fitting can lead to loss of transmission fluid, which could result in loss of control and death or serious injury. (00449c) -J04568
NOTE Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty. 1. See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing the O-ring onto the threaded portion of the clutch cable end. 2. Install the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). 3. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet. FLTR Models with Fairing Lowers 1. See Figure 1. Carefully twist the clutch cable around the coiled opening in the clutch cable guide (2) with the eyelet toward the left handlebar. 2. Route the clutch cable assembly down from the clutch cable clamp while crossing to the right side of the vehicle. Run the cable between the inboard side of the right frame downtube and the outboard side of the voltage regulator. 3. The clutch cable clamp, mounted on the engine guard, has two fingers, an upper and a lower. Feed the cable assembly under one finger and over the other. 4. Finish the installation of the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). NOTE See Figure 2. Adjust the clutch cable clamp to 2.25 ± 0.25 in. (57.15 ± 6.35 mm) as measured from the inside lower left fairing mount to the clutch cable clamp. 5. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet.

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HARLEY DAVIDSON TLE/TLE-ULTRA SIDECAR ATTACHMENT KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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REMOVAL NOTES Refer to the service manual for more information on these generalized steps. Save all removed parts (unless otherwise noted) for installation of this kit or for motorcycle operation without the sidecar. 1. For TLE-Ultra Models: Remove both lower fairings. 2. Remove the bolt and lockwasher securing the right passenger footrest bracket and remove the bracket with footrest. 3. Remove the three right side exhaust heat shields. Some models may require removal of the right side exhaust pipes. 4. Remove stock clutch cable. 5. Remove rear master cylinder/rear brake pedal assembly. Remove rear brake pedal from master cylinder assembly. Remove and save rubber pedal pad and brake pedal. Discard cotter pin. 6. Cut the cable straps holding front oxygen sensor connector to frame bracket. 7. Remove wire harness/brake line clip from right lower frame tube. INSTALLATION New Clutch Cable Installation 1. Refer to the service manual and follow instructions to remove stock clutch cable. 2. Refer to the service manual and follow instructions to connect the new clutch cable to clutch hand lever. 3. For FLHT/C/CU: Follow the instructions in the service manual to route new clutch cable through fairing. 4. For FLHR/C Models: Capture the cable in a clamp at the left upper passing lamp bolt. On FLTR models, capture the cable in a clamp at the left upper bolt securing the speedometer and tachometer housing to the upper fork bracket. These locations are identical with stock cable routing. 5. See Figure 1. Route clutch cable down along left frame downtube (1). 6. Continue to route cable down between left front engine isolator and crankcase. Clutch cable will cross to the right side of motorcycle beneath the crankcase, to the clutch release cover on the right side of the transmission. 7. Install clutch cable fitting into clutch release cover. Refer to the service manual. NOTES The final positioning and attachment of the clutch cable and clutch cable adjustment will be performed after sidecar mounts have been installed. Verify that the clutch cable and the rear brake line do not make contact. Damage could result. 1 2 3 is05785 1. Downtube 2. Clutch cable 3. Route clutch cable behind left front engine iso- lator Figure 1. Route Clutch Cable Relocating Oil Pressure Sending Unit NOTES Perform this procedure on all models equipped with an oil pressure gauge or Police models. All other models proceed to “Master Cylinder Assembly/Rear Brake Pedal Modification.” 1. Remove cable strap securing oil pressure wire harness to frame. 2. Locate the latch on connector to oil pressure sender (next to lower right frame downtube). Raise latch on connector and disconnect connector from oil pressure sender. 3. Remove the oil pressure sender using a 1-1/16 inch open- end crowfoot wrench. 4. See Figure 16. Coat threads of elbow (44) with Loctite 565 and install into crankcase oil pressure sender threads. 5. See Figure 2. Install elbow (1) until snug so open end is in the five-o’clock position (2). Do not over-tighten or crankcase may be damaged. 6. Coat threads of oil pressure sender with Loctite 565 and install into 90 degree brass elbow. Use a 1-1/16 inch open- end crowfoot and tighten to 96-120 in-lbs (11-14 Nm) . 7. Install connector on oil pressure sender unit. Verify that slight clearance to the right engine isolators is present. Adjust position of elbow as required to provide clearance

HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL THIS KIT. The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have your Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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2008 Honda CBR1000RR Clutch Inner Installation PROCEDURE

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Filed Under (Honda) by admin on 23-04-2011

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Refer to the 2008 CBR1000RR Service Manual for specific removal instructions. While completing this procedure, be careful not to damage the covers, cowls, or any other components. 1. Remove the air intake cover (page 3-8). 2. Remove the upper inner cover (page 3-9). 3. Remove the lower cowl (page 3-9). 4. Remove the right middle cowl (page 3-10). 5. Remove the right crankcase cover (page 10-5). Clutch Removal (page 10-7) 6. Remove the starter idle gear and shaft. 7. Remove the snap ring and stopper ring. 8. Remove the clutch lifter piece and plate. 9. Unstake the clutch center lock nut. Be careful not to damage the mainshaft threads. 10. Hold the pressure plate with the special tool. You must use the special tool (Clutch Holder, T/N 070MB-MFLA100) when removing the lock nut. Using an impact wrench will damage the main shaft threads. Clutch Holder: 070MB-MFLA100 (autoshipped in May 2008) 11. Remove the clutch center lock nut and washer and discard the lock nut as shown on top of page 3 12. Remove the clutch spring holder, spring seat, and two clutch springs. 13. Remove the spring seat. 14. Remove the following: • Pressure plate
• Spring seat • Judder spring • Clutch disc A • Clutch plate A • Seven clutch discs B • Clutch disc C  Clutch center NOTE: Do not remove the clutch outer. New Clutch Installation (page 10-20) NOTE: The new clutch disc assembly has a dif- ferent order of plates than the illustration shown in the Service Manual. Keep note of this when repairing updated units.
15. Install the new clutch disc assembly with- out removing the setting bolts. Rotate the main shaft to align the clutch disc assem- bly with the main shaft spline. 16. Slightly loosen the setting bolts. 17. Rotate clutch disc C to align its tabs into clutch outer shallow slots, then fully install the clutch disc assembly. 18. Remove and discard the setting bolts. 19. Install the spring seat

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HARLEY DAVIDSON DETACHABLE WINDSHIELD AND DOCKING HARDWARE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 05-02-2011

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These kits fit 1984 and later FXST, FXSTB, FXSTC, and 1993 and later FXDWG model motorcycles when equipped with passing lamps. INSTALLATION 1. To protect against scratches, cover gas tank and front fender before installation. is 01985 Figure 1. New Clutch Cable Routing 2. For FXSTB Models: Proceed to Step 3. For all except FXSTB: See Figure 1. Relocate the clutch cable to the inside of the handlebars as follows: a. Locate cable adjuster halfway along clutch cable by the front frame downtube and slide off rubber boot. b. Holding cable adjuster with 1/2 inch wrench, loosen jam nut using a 9/16 inch wrench. Back jam nut away from cable adjuster. Move adjuster toward jam nut to introduce a large amount of free play at hand lever. c. Remove small snap ring from pivot pin groove at bottom of clutch lever bracket. Remove pivot pin and clutch hand lever from bracket. Remove anchor pin and clutch cable eyelet from clutch hand lever. d. See Figure 1. Route clutch cable to the inside of the handlebars and reconnect clutch cable to clutch lever. e. See Figure 2. Turn cable adjuster away from jam nut until slack is eliminated at hand lever. Pull clutch cable ferrule away from clutch lever bracket to check free play. Turn cable adjuster to obtain 1/16-1/8 inch (1.6- 3.2 mm) free play between end of cable ferrule and clutch lever bracket. f. Hold adjuster with 1/2 inch wrench. Using 9/16 inch wrench, tighten jam nut against cable adjuster. Cover cable adjuster mechanism with rubber boot

Kawasaki KLR 650 Hydraulic Clutch Installation Manual

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Filed Under (Yamaha) by admin on 08-11-2010

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Now, the clutch safety interlock switch. The picture above shows the safety switch contacts. Once you removed the 2 screws holding it to the stock lever, you will need to cut the copper plate on the switch. There are 3 wires: Green, Black with yellow and Blue. You do not use the green wire. You will need to attach the supplied terminals to the remaining wires and slip the supplied rubber boot over them as you attach them to the hydraulic clutch lever. In the photos, the boot is installed and also removed, and with my finger, I am pointing to its location. I did not bother to install the clutch interlock switch and removed the wiring harness completely, but unplugging it from the connector behind the instrument panel. Next, you must remove the clutch cable from the lever in order to pass the cable under the steering head he picture above shows the attachment at the clutch actuator Once the clutch cable is removed from the lever, remove the bolt holding it at on the engine case and disconnect the clutch cable from the pivot. The easiest way to do this is to pull out the clutch pivot assembly and the long “spike” out of the clutch plate hole. (It only goes back in one way, so you can’t mess it up.) he picture above shows that the routing is the same as the original clutch cable. With the hydraulic clutch assembly, pass the stainless steel braided line to the clutch “pivot” point at the engine casing. Attach the clutch cable to the “pivot” while it is removed from the engine, then insert the “spike” into the clutch plates hole (it can only go in one way).

HARLEY DAVIDSON BILLET CLUTCH CABLE ADJUSTER COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 29-03-2011

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INSTALLATION 1. Dyna Models: Remove the plastic clip that fastens the clutch cable to the frame downtube just below the clutch cable adjuster and boot. Leave the clip above the adjuster in place. Softail Models: Remove the plastic clip and screw that attaches the clutch cable to the frame downtube just above the clutch cable adjuster and boot. 2. ALL Models: See Figure 1. Cut the original rubber boot (B) from the clutch cable (A). Make sure that the clutch cable covering is not cut or damaged. 3. Obtain the two halves of the clutch cable adjuster cover (items 1 and 2) and two cushions (8). Peel the paper backing from one cushion (8), and center the cushion on the inside of one cover half. Repeat for the other cushion and cover half. 4. Obtain the two screws (7) from the kit. Position the cover halves on each side of the cable adjuster, and align the screw holes at each end. Place a drop of Loctite 243 – Blue on the screw threads, and fasten the cover halves with the two screws. Tighten to 21 in-lbs (2.4 Nm)

KAWASAKI CLUTCH KIT INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 25-10-2010

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1. Remove the key from the ignition switch. Loosen the vent hose on the cover. Remove the clutch cover bolts (10mm socket) and take the clutch cover off. You will need to unplug the wires from the electric actuator and small sensor in the center of the clutch cover to totally remove the cover. To unplug the wires from the sensors, follow the wires to the connections under the plastic side panel and unplug at that location. 2. Remove the primary clutch bolt (19mm socket). This is a left threaded bolt. Insert clutch puller by hand (right hand threads) and tighten until clutch pops off the shaft. This tool is available from EPI, part number PCP-10. Loosen the secondary clutch nut (27mm socket) and remove both clutches at the same time. When you slide the secondary clutch of the machine there are four metal roller pins inside the center shaft of the secondary clutch. These will normally stay in place but if one does fall out refer to assembly instructions in step #6. 3. Disassemble the primary clutch by removing the eight bolts on the cover plate (10mm socket) and remove the spring. Remove one nut (10mm) on the bolt that holds the weight in place, slide the pin out of the clutch and remove the weight. Install EPI weight making sure the tip of the weight is resting on the inside ledge of the clutch. Slide bolt through the holes in the clutch and the weight and install the nut. Repeat this step for the other three weights. NOTE: If your kit has two different gram weights, for example two 54 and two 56 weights, be sure to place them directly across from each other (or every other one). This keeps the clutch in balance . 4. Install the EPI spring and bolt the clutch cover back on using a criss-cross pattern to tighten down the cover. There is a mark on the cover plate and the spider usually in the form of a dot or arrow in the casting. These are alignment marks and must line up when the clutch is assembled. 5. EPI recommends cleaning your clutches when you have them off your machine. Use a clean rag or towel with contact or brake cleaner that does not leave any oily film. Clean all parts of the clutch except for the clutch bushings. Solvent can damage your bushings; just use a dry rag to clean them

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HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/IDLE CABLE KITS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be installed in the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3 2 1 is00825 1. Brake lever 2.5/32 inch (4 mm) cardboard insert 3. Brake lever bracket Figure 1. Install Cardboard Insert 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 3 4 1 2 5 is 02071 1. Upper switch housing 2. Lower switch housing 3. Throttle cable adjuster 4. Idle cable adjuster 5. Adjuster jam nut Figure 2. Handlebar Throttle Control 4. Remove the right upper and lower switch housing screws. 5. Loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw and flat washer. NOTE If possible, leave the friction shoe in place. The friction shoe is a loose-fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken. 6. See Figure 3. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings. 1 2 4 3 is 02072 1. Throttle cable 2. Idle cable 3. Brass ferrule 4. Notch Figure 3. Throttle/Idle Control Cables 7. Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Remove cables with retaining rings from switch housing. Apply a drop of light oil on the retaining ring, if necessary, to help in removal. NOTE If installing different handlebars, measure the change in distance that will be required from the end of the cable housing to the throttle grip. Compare this additional required length to the cables provided in the kit. If the cables are more than 2.0 inches (51 mm) longer or more than 1.0 inch (25 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. Install proper length throttle cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00396b) 8. Follow instructions in the applicable service manual and remove air cleaner and backplate.

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