meanbean
03-04-2007, 02:00 PM
I did the clutch and brake cables last night. They are very easy to do.
1. As always, read the manual. I'm impressed with the manual; HD has some good technical writers.
2. Drain the tranny fluid. Remove the tranny side cover.
http://www.toughbeans.com/assets/images/autogen/a_apes_019.jpg
3.Remove the clutch cable from the tranny side cove assembly. The manual has some good pics of this assembly. You will need a good pair of snap ring pliers for this. Note the "O" ring on the end of the cable. My O ring was in good shape but I used the new one that came with the cable. The Magnum Sheilding cables came with everything, O rings, washers, ferrule ends, even a new clutch lever pin.
http://www.toughbeans.com/assets/images/autogen/a_apes_021.jpg
http://www.toughbeans.com/assets/images/autogen/a_apes_023.jpg
http://www.toughbeans.com/assets/images/autogen/a_apes_024.jpg
4. Install the new cable in the housing and bolt the housing back on the bike following the torque sequence in the manual. Fill the tranny with fluid, don't forget to put the plug back in. Use a new O ring on the plug and wrap the threads with teflon tape.
5.Route the cable up to the bars and install it on the lever.
6.Adjust the cable according to the manual. I'll re-adjust the cable when I get the bike back on the road. I like it a little tighter than the manual specifies, I don't like any slop going in and out of the friction zone.
Front Brake:
1. This is as easy as it gets.
2. Drain the fluid from the master cylinder.
3.Take off the old cable.
4. Put on the new cable. Don't re-use the old banjo bolt washers, use new ones.
5. Fill the master cylinder with brake fluid. Make sure you use the correct fluid, mine takes DOT4, different DOT numbers are not compatible with each other.
6. Bleed the air from the system.
7. Zip tie the clutch and brake cables in place and re-install the cable clamps. Turn the handle bars from side to side and make sure the cables don't bind, pull or hang up on anything.
I have the hand controls temporarily attached because I have new grips and levers on order and they have yet to arrive.
http://www.toughbeans.com/assets/images/autogen/a_apes_025.jpg
1. As always, read the manual. I'm impressed with the manual; HD has some good technical writers.
2. Drain the tranny fluid. Remove the tranny side cover.
http://www.toughbeans.com/assets/images/autogen/a_apes_019.jpg
3.Remove the clutch cable from the tranny side cove assembly. The manual has some good pics of this assembly. You will need a good pair of snap ring pliers for this. Note the "O" ring on the end of the cable. My O ring was in good shape but I used the new one that came with the cable. The Magnum Sheilding cables came with everything, O rings, washers, ferrule ends, even a new clutch lever pin.
http://www.toughbeans.com/assets/images/autogen/a_apes_021.jpg
http://www.toughbeans.com/assets/images/autogen/a_apes_023.jpg
http://www.toughbeans.com/assets/images/autogen/a_apes_024.jpg
4. Install the new cable in the housing and bolt the housing back on the bike following the torque sequence in the manual. Fill the tranny with fluid, don't forget to put the plug back in. Use a new O ring on the plug and wrap the threads with teflon tape.
5.Route the cable up to the bars and install it on the lever.
6.Adjust the cable according to the manual. I'll re-adjust the cable when I get the bike back on the road. I like it a little tighter than the manual specifies, I don't like any slop going in and out of the friction zone.
Front Brake:
1. This is as easy as it gets.
2. Drain the fluid from the master cylinder.
3.Take off the old cable.
4. Put on the new cable. Don't re-use the old banjo bolt washers, use new ones.
5. Fill the master cylinder with brake fluid. Make sure you use the correct fluid, mine takes DOT4, different DOT numbers are not compatible with each other.
6. Bleed the air from the system.
7. Zip tie the clutch and brake cables in place and re-install the cable clamps. Turn the handle bars from side to side and make sure the cables don't bind, pull or hang up on anything.
I have the hand controls temporarily attached because I have new grips and levers on order and they have yet to arrive.
http://www.toughbeans.com/assets/images/autogen/a_apes_025.jpg