Replacing the clutch cable

Energy One
ChopperJeff

ChopperJeff

Active Member
My clutch cable snapped and the dealer wants 1.5 hours labor to replace it. This will bring the total cost to $230!!!

How tough is it to replace the clutch cable?

Thanks.
 
ChopperJeff

ChopperJeff

Active Member
The dealer claims that the pipes have to be removed as it's a right-side drive, hence the added time. At $110/hour labor rate though, I'd just assume do it myself if I can.
 
Raywood

Raywood

The Pirate
Staff member
Calendar Participant
Troop Supporter
You can. Order the cable from Nelsom or Vicky and when you get ready we can talk you through it but it's easy and the hardest part will be the ball and ramp assembly inside the tranny cover.

Can't remember what pipes you have so can't tell you if you need to remove them but if they block the tranny cover then you will most likely have to remove at least the front pipe so get a new gasket for it.

:flag:
 
chacha

chacha

Chaff Your EHC!!
Calendar Participant
good point. Add 30 minutes for the pipes. (mine don't go that far) 110/hr is nuts!!
 
Staffy

Staffy

Active Member
You can do it - we can help:lol: :lol: :lol: Sounds familiar....
Hang in ther for a few, GASMAN to the rescue with a "How To" you can count on him and the REST OF THE CREW to help out. Nothing like a little weekend grease and the pleasure of doing it yourself. Not always about the $$$$
 
Q

Que

Member
Just got off the phone with my Big Dog Dealer and they have no idea how long the clutch cable should be on my 2007 Chopper. The previous owner had the cable replaced at the dealer and the housing is too long. Meaning that the inner cable (wire) is too long. The adjustments are all the way out and there is still too much slack. Even checked the adjustment on the pushrod. I noticed that another post stated that his K9 cable is 67". Mine should be the same lenght. I don't want to remove the cable just to know how long the housing is without a new one or the right one to install. It just worries me knowing this cable is adjusted all the way out. It even flexes at the adjustment because there's only about one thread screwed in with the locknut barely grabbing.
 
S

stryfox

Active Member
$110 an hour to fix a bike!!!!!
I restore cars and we only charge $69 an hour!!!!
Do it yourself, spend the money you saved on something fun.....
 
A

adamthisis

Guest
Send your cable back to Barnett, they will fix it for free you just have to pay for shipping.
 
V

V

Guru
Que said:
Just got off the phone with my Big Dog Dealer and they have no idea how long the clutch cable should be on my 2007 Chopper. The previous owner had the cable replaced at the dealer and the housing is too long. Meaning that the inner cable (wire) is too long. The adjustments are all the way out and there is still too much slack. Even checked the adjustment on the pushrod. I noticed that another post stated that his K9 cable is 67". Mine should be the same lenght. I don't want to remove the cable just to know how long the housing is without a new one or the right one to install. It just worries me knowing this cable is adjusted all the way out. It even flexes at the adjustment because there's only about one thread screwed in with the locknut barely grabbing.
Click to expand...
Somethin doesn't sound right, If a cable assembly is to long it will still work but excess will be in the way maybe rubbing the tank etc. From what you're sayin the inner (actual cable) is to long for the cable housing. any possibility the cable is stretched/ready to break or somebody buggered it before you got the bike?

Compentent dealer should be able to provide you with the correct part with know problems. Might call some of the sponsers here on the site. :2thumbs:

V
 
TCALZ06

TCALZ06

Well-Known Member
Compentent dealer should be able to provide you with the correct part with know problems. Might call some of the sponsers here on the site. :2thumbs:

V[/QUOTE]

Very true. It might take you 2 hours the first time if you have never adjusted your clutch. my old dealer never got my adjustment right and neutral was always a struggle. Also you can grease the clutch rod at the same time and do some cleaning.
It is my feeling that the grease on that rod helps a lot with the clutch operation. When I greased my rod it looked like the dealer had never done it. I think lack of grease creates a lot of drag on the clutch operation
 
RRRUFF

RRRUFF

Well-Known Member
Que said:
Just got off the phone with my Big Dog Dealer and they have no idea how long the clutch cable should be on my 2007 Chopper. The previous owner had the cable replaced at the dealer and the housing is too long. Meaning that the inner cable (wire) is too long. The adjustments are all the way out and there is still too much slack. Even checked the adjustment on the pushrod. I noticed that another post stated that his K9 cable is 67". Mine should be the same lenght. I don't want to remove the cable just to know how long the housing is without a new one or the right one to install. It just worries me knowing this cable is adjusted all the way out. It even flexes at the adjustment because there's only about one thread screwed in with the locknut barely grabbing.
Click to expand...
Que, dealer may have misplaced one or more of the ramp balls in the actuator. Actuator has to be opened up to get the cable off, and they may not have put everthing back in place before they closed it up. And it is also possible the clip on the bottom side of the hand control lever is not right also. Just some thoughts that might help.:job:
 
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