DIY – Clutch Cable on a 1971 Harley Davidson FLH
With every day use, a clutch cable on a 1971 Harley Davidson FLH can stretch and wear out. The cable can even break if too worn. This is not the end of the ride. With some tools and a new cable, the clutch cable can be replaced and the bike is back on the road in no time. Be sure to gather all the things you need before starting this project. You will need, a set of screwdrivers, a set of sockets, metric or SAE sizes, a socket wrench, a combination wrench set, and the service manual for your bike.
Tighten the cable adjustment nut in the middle of the cable all the way. This will loosen the cable adjustment. The lock nut located on the clutch lever cable is loosened next. This is done by squeezing the cable adjuster until it is flush with the clutch lever. The grooves along the clutch lever and adjuster should line up. Take the end cap off of the clutch lever. Draw the cable out of the grooves.
Take the clutch lever cover off if the cable is behind it. Loosen the lock nut. Turn the adjuster to the left until it comes off of the clutch release. Take the inner cable out through the groove on the clutch release. Take the end of the cable off of the clutch release catch. Pay attention to the path of the cable along the handlebars. Remove the cable and any mounting bolts or brackets that may be present.
Grease up the cable and tighten the middle adjuster. Place the end in the catch on the clutch release and fit loosely. Guide the cable to the lever. Be sure to follow the exact path as the old one. Glide the cable into the groove for the clutch lever. Secure until it is seated, but leave it a bit loose. Slide the knobby end in the space on the lever.
Adjust the adjuster closest to the engine to remove any slack. Using the adjuster to the correct amount of play. While holding the adjuster in place, tighten the lock nut. The same should be done to the center adjuster. Complete the adjustment at the lever. Turn the adjuster to the right. Leave about an eighth of an inch slack at the lever. Check the adjustment and continue until the cable is set correctly. Replace the clutch cover.