"LE" SERIES CLUTCH CABLE KIT
J045682021-03-18
GENERAL
Kit Numbers
Table 1. Kit Contents
Diamond-Black Kit | Diamondback Kit | Length |
|---|---|---|
N/A | 37200336A | 74.00 inch |
N/A | 37200337A | 78.50 inch |
37200174A | 37200173A | 58.69 inch |
38967-10B | 38921-09B | 62.69 inch |
37200049B | 38922-09B | 64.69 inch |
37200175A | 38923-09B | 66.69 inch |
37200050B | 38924-09B | 68.69 inch |
38981-10B | 38925-09B | 70.69 inch |
38983-10B | 38926-09B | 72.69 inch |
38874-10B | 38847-09B | 57.69 inch |
38941-09C | 38848-09B | 58.69 inch |
38940-09C | 38849-09B | 60.69 inch |
38877-09C | 38850-09B | 62.69 inch |
38818-10B | 38851-09B | 64.69 inch |
38875-09C | 38852-09B | 66.69 inch |
38916-09C | 38854-09B | 68.69 inch |
38973-10B | 38856-09B | 70.69 inch |
38975-10B | 38857-09B | 72.69 inch |
38977-10B | 38858-09B | 74.69 inch |
38979-10B | 38859-09B | 76.69 inch |
N/A | 38860-09B | 78.69 inch |
37200136B | 37200134B | 48.25 inch |
37200008C | 37200056B | 52.75 inch |
37200058B | 38737-09C | 54.75 inch |
38939-09D | 38745-09C | 57.50 inch |
37200149A | 37200151A | 58.75 inch |
38911-09D | 37200048B | 61.75 inch |
37200496 | 37200480 | 68.25 inch |
37200495 | 37200479 | 72.31 inch |
37200493 | 37200477 | 75.06 inch |
37200492 | 37200476 | 64.31 inch |
37200491 | 37200475 | 69.06 inch |
37200490 | 37200474 | 70.25 inch |
37200489 | 37200473 | 78.56 inch |
37200488 | 37200472 | 74.31 inch |
37200503 | 37200487 | 73.75 inch |
37200502 | 37200486 | 66.75 inch |
37200501 | 37200485 | 72.75 inch |
37200500 | 37200484 | 70.75 inch |
37200499 | 37200483 | 69.75 inch |
37200498 | 37200482 | 67.75 inch |
37200497 | 37200481 | 65.75 inch |
NOTE
The "LE" Series Clutch Cable Kits are available in various cable lengths. Shorter or longer cables may be necessary when modifications (that is, optional handlebars) have been made to the motorcycle. See the Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts Catalog for fitment and length information.
Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty.
Installation Requirements
Dyna, Softail and Touring models require separate purchase of a clutch release cover gasket. See Table 2.
Table 2. Clutch Release Cover Gasket Usage
Model | Gasket Part Number |
|---|---|
2005 and earlier Dyna | 36801-87C |
2006-2017 Dyna | 36805-06 |
2006 and earlier Softail | 36801-87C |
2007 and later Softail | 36805-06 |
2006 and earlier Touring | 36801-87C |
2007 and later Touring | 36805-06 |
WARNINGRider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
CLUTCH CABLE REMOVAL
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNINGDisconnect 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. | Record wire routing and cable strap locations before removal. Install new cable straps in the proper 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 is required from the end of the cable housing to the clutch lever. | |
| WARNING 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 in (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
WARNINGDo 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)
NOTE
Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty.
Verify that the clutch cable is properly supported when inserting the threaded fitting into the clutch release cover. Side-loading the clutch cable will increase the chances of damage to the threads.
| 1. | See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing onto the threaded portion of the clutch cable end. | |
| 2. | Tighten clutch cable fitting to clutch release cover. Torque: 10–13 N·m (90–120 in-lbs) clutch cable fitting | |
| 3. | After installation, follow the instructions in the "Final Assembly" and "Clutch Cable Adjustment" sections in this instruction sheet. |
2007-2015 FLTR/X Models with Fairing Lowers
| 1. | See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing onto the threaded portion of the clutch cable end. | |
| 2. | 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. | |
| 3. | 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. | |
| 4. | 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. | |
| 5. | Tighten clutch cable fitting to clutch release cover. Torque: 10–13 N·m (90–120 in-lbs) clutch cable fitting 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. | |
| 6. | After installation, follow the instructions in the "Final Assembly" and "Clutch Cable Adjustment" sections in this instruction sheet. |
| 1 | Cable clamp adjuster |
| 2 | Cable guide (FLTRSEI models only) |
| 3 | Clutch cable |
| 4 | Holding fingers |
Figure 1. Clutch Cable Routing, FLTR Models with Fairing Lowers
| 1 | Guide pin hole location |
| 2 | New cable guide |
| 3 | 2.25 +/- 0.25 in. (57.15 +/- 6.35 mm) |
| 4 | Clutch cable |
Figure 2. Clutch Clamp Mounting Measurement FLTR Models with Fairing Lower
FLHT/C/CU and FLHX Models
| 1. | See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing onto the threaded portion of the clutch cable end. | |
| 2. | See Figure 11. Tighten clutch cable fitting to clutch release cover. Torque: 10–13 N·m (90–120 in-lbs) clutch cable fitting | |
| 3. | Replace stock grommet with grommet (6). | |
| 4. | After installation, follow the instructions in the "Final Assembly" and "Clutch Cable Adjustment" sections in this instruction sheet. |
2007 - 2015 FLHR Models
| 1. | See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing onto the threaded portion of the clutch cable end. | |
| 2. | See Figure 11. Discard the stock P-clamp on the upper fork bracket. Replace with P-clamp (8). | |
| 3. | Tighten clutch cable fitting to clutch release cover. Torque: 10–13 N·m (90–120 in-lbs) clutch cable fitting | |
| 4. | After installation, follow the instructions in the "Final Assembly" and "Clutch Cable Adjustment" sections in this instruction sheet. |
Dyna Models
| 1. | See Figure 3. Apply a light coat of clean engine oil to the new O-ring. Install the O-ring onto the threaded portion of the clutch cable (3). Insert the clutch cable fitting (2) into the clutch release cover. Do not exert any sideways force on the fitting during installation. Do not tighten the cable fitting at this time. | |
| 2. | Connect the cable end to the coupling (4). Rotate the ramps for best access. Install the coupling on the inner ramp. Place the ramp assembly in position in the clutch release cover. | |
| WARNING Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) | ||
| 3. | Install the retaining ring (1). Position the retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). | |
| 4. | See Figure 4. Place the new gasket (purchased separately) on the clutch release cover Install the cover. Tighten the six screws in the order shown to . Torque: 9.5–10.2 N·m (84–108 in-lbs) hex socket screw | |
| 5. | Tighten clutch cable fitting to clutch release cover. Torque: 10–13 N·m (90–120 in-lbs) clutch cable fitting NOTE Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty. | |
| WARNING 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) | ||
| 6. | Route the cable per the instructions in this Step for your model: |
| 1 | Retaining ring |
| 2 | Cable fitting |
| 3 | Clutch cable |
| 4 | Ramp coupling |
| 5 | Inner ramp |
| 6 | Hook of ramp assembly |
Figure 3. Clutch Cable Connection
Figure 4. Clutch Release Cover Screws
Cable Routing: 1996-2005 Dyna Models
- All Dyna models: See Figure 5. Route the clutch cable (1) from the clutch release cover, under the frame and across to the left side of the vehicle. Insert the cable into the clip (2) at the bottom left side of the frame. Continue routing the cable up in front of the frame downtube.
- All Dyna models (except FXDWG): Route the cable inside the left fork tube between the upper and lower fork brackets and along the left side of the headlamp.
- FXDWG models: Route the cable behind the front fork upper bracket and over the handlebar.
- FXDWG2 and FXDWG3 models: Also pass the clutch cable through the clutch cable guide ring.
- All Dyna models: After installation, follow the instructions in the "Final Assembly" and "Clutch Cable Adjustment" sections in this instruction sheet.
| 1 | Clutch cable |
| 2 | Clutch clip |
Figure 5. Bottom Clutch Cable Clip
Cable Routing: 2006-2017 Dyna Models
- All Dyna models: See Figure 5. Route the clutch cable (1) from the clutch release cover, under the frame and across to the left side of the vehicle. Insert the cable into the clip (2) at the bottom left side of the frame.
- See Figure 6. Verify that there is approximately 25.4 mm (1.0 in) clearance between the cable (2) and the front engine mount (3).
- Continue routing the cable up the side of the frame downtube.
- All Dyna models (except FXDB): See Figure 7. Route the clutch cable (1) behind the front fork upper bracket (2) and under the handlebar (3).
- All Dyna models: After installation, follow the instructions in the "Final Assembly" and "Clutch Cable Adjustment" sections in this instruction sheet.
| 1 | Approximately 1.0 in. (25.4 mm) clearance |
| 2 | Clutch cable |
| 3 | Front engine mount |
Figure 6. Clearance Between Clutch Cable and Front Engine Mount (2006-2017 Dyna Models)
| 1 | Clutch cable |
| 2 | Front fork upper bracket |
| 3 | Handlebar |
Figure 7. Clutch Cable Routing, Upper (2006-2017 Dyna Models Except FXDB)
Final Assembly
NOTE
Some of the clutch cables in these kits contain a loose piece of clear Teflon® heat shrink tubing on the upper cable for added abrasion resistance. This heat shrink tubing has been installed but not shrunk.
If the cable makes rubbing contact with motorcycle (that is, at the upper fork clamp, at a wireform guide, etc.), position the heat shrink tubing so it is centered at the location of contact and shrink the tubing in place using a radiant heat source (such as the Robinair Heat Gun with Heat Shrink Attachment) (DO NOT use the Ultratorch!).
If the Teflon® tubing has an instruction label attached, remove the label before heat shrinking.
Install Cable Straps
NOTE
Accessory clutch cables are to be mounted and secured to the motorcycle in the same manner as OE cables. When using cables with non-OE handlebars attention needs to be given to routing and anchoring of cables for freedom of operation for both the cable and steering.
See Figure 11. Double-loop cable strap(s) (1) are included in the kit to hold the clutch cable adjuster away from the frame and secure it to the vehicle.
| 1. | Remove and discard metal clips or straps holding stock clutch cable and place double-loop straps in the same locations. For Dyna and Sportster Models: Use two double-loop straps (one above the adjuster, one below). On the strap above the adjuster leave enough slack in loop around cable to allow adjuster sleeve to pass through freely when performing service adjustments. For Softail and Touring Models: Use one double-loop strap below the adjuster to attach to frame tubes. | |
| 2. | For Softail Models: Use a single loop cable strap (9) from kit to secure clutch cable to lower frame tube to hold clutch cable away from exhaust. | |
| 3. | 2021 and later Models: Use a cable strap to secure clutch cable to handlebar and maintain cable routing. | |
| 4. | See Figure 8. Wrap a cable strap (1) around the downtube (2). Insert the end into the head (3) of the cable strap. | |
| 5. | See Figure 9. Wrap cable strap around the clutch cable (2). Insert the end into the head of the cable strap. Pull the cable strap tight to secure the clutch cable to the downtube. Trim the end of the cable strap (3). Repeat as necessary. | |
| 6. | Fill the transmission with lubricant following the instructions in the service manual. | |
| WARNING Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a) WARNINGConnect positive (+) 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. (00068a) | ||
| 7. | Connect the battery cables, positive cable first or connect the main fuse. |
| 1 | Cable strap |
| 2 | Downtube |
| 3 | Head of cable strap |
Figure 8. Install Cable Strap to Downtube
Clutch Cable Adjustment
NOTE
See Figure 10. Cable adjuster cover (4) slide easier if the cable is straightened in one hand while sliding cover with other hand. Do not damage the outer covering on the clutch cable.
| 1. | See Figure 10. Slide clutch cable adjuster cover (4) to access jamnut (3). NOTE Adjustment requires two 7/16-in wrenches for the jamnut and cable adjuster (1). | |
| 2. | Adjust cable following the instructions in the service manual. NOTE Both the clutch and the free play in the clutch cable must be adjusted when installing this kit. | |
| 3. | While adjusting the free play in the clutch cable, hold the clutch lever side of the adjuster with one wrench while using the other wrench to rotate the transmission end of the adjuster. Twisting the clutch lever side of the adjuster could result in damage to the outer jacket of the clutch cable. | |
| 4. | When the clutch adjustment has been completed, tighten jamnut against the clutch lever side of the adjuster. Tighten nut. Torque: 13.6 N·m (120 in-lbs) jamnut | |
| 5. | Slide clutch cable adjuster cover down until it hits the stop. |
| 1 | Bottom of clutch cable fitting |
| 2 | Clutch cable |
| 3 | End of cable strap |
Figure 9. Install Cable Strap to Clutch Cable
| 1 | Cable adjuster transmission end |
| 2 | Cable adjuster clutch lever end |
| 3 | Jam nut |
| 4 | Cable adjuster cover |
| 5 | Transmission end |
| 6 | Clutch lever end |
Figure 10. Clutch Cable Adjuster
SERVICE PARTS
Figure 11. Service Parts: Clutch Cable Kits
Table 3. Service Parts Table
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
38737-09C, 38745-09C, 38939-09D, 38911-09D, 38847-09B, 38848-09B, 38849-09B, 38850-09B, 38851-09B, 38852-09B, 38854-09B, 38856-09B, 38857-09B, 38858-09B, 38859-09B, 38860-09B, 38916-09C, 38875-09C, 38818-10B, 38877-09C, 38940-09C, 38941-09C, 38874-10B, 38973-10B, 38975-10B, 38977-10B, 38979-10B, 37200008C, 37200048B, 37200056B, 37200058B, 37200137B, 37200134B, 37200149A, 37200151A | 1 | Cable strap, double-loop (2) | 10360 |
2 | O-Ring | 11179 | |
3 | Clutch cable (includes Item 4) | Not sold separately | |
4 | Protective tubing (if applicable) | Not sold separately | |
5 | Anchor Pin | 45036-88 | |
9 | Cable strap, single-loop | 10039 | |
38921-09B, 38922-09B, 38923-09B, 38924-09B, 38925-09B, 38926-09B, 38967-10B, 38981-10B, 38983-10B, 37200049B, 37200050B, 37200173A, 37200174A, 37200175A, 37200336A, 37200337A | 1 | Cable strap, double-loop (2) | 10360 |
2 | O-Ring | 11179 | |
3 | Clutch cable (includes Item 4) | Not sold separately | |
4 | Protective tubing (if applicable) | Not sold separately | |
5 | Anchor Pin | 45036-88 | |
6 | Grommet (FLHT/C/CU and FLHX models only) | 11445 | |
7 | Anchor Pin | 38900-08 | |
8 | P-clamp (not shown) (FLHR models only) | 10076 | |
37200481, 37200482, 37200483, 37200484, 37200485, 37200486, 37200487, 37200497, 37200498, 37200499, 37200500, 37200501, 37200502, 37200503 37200472, 37200473, 37200474, 37200475, 37200476, 37200477, 37200479, 37200480 37200488, 37200486, 37200490, 37200491, 37200492, 37200493, 37200495, 37200496 | 1 | Cable strap, double-loop (2) | 10360 |
2 | O-Ring | 11179 | |
3 | Clutch cable (includes Item 4) | Not sold separately | |
4 | Protective tubing (if applicable) | Not sold separately | |
5 | Anchor Pin | 38900-08 | |
9 | Cable strap, single-loop | 10039 |