HANDLEBAR CLUTCH CABLE
941004122024-01-24
GENERAL INFORMATION
Table 1. General Information
Kits | Suggested Tools | Skill Level(1) |
|---|---|---|
37200575, 37200576, 37200577, 37200578, 37200579, 37200580, 37200581, 37200582, 37200583, 37200584, 37200586, 37200587, 37200588, 37200590 | Safety Glasses, Torque Wrench |  |
(1) Tightening to torque value or other moderate tools and techniques required
KIT CONTENTS
Figure 1. Kit Contents: Handlebar Clutch Cable
Table 2. Kit Contents: Handlebar Clutch Cable Kit
 | Verify that all contents are present in the kit before installing or removing items from vehicle. | ||||
|---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
 | 1 | 1 | Clutch Cable | 37200599 | Kit 37200575, Diamondblack |
| 37200598 | Kit 37200576, Diamondblack | |||
| 37200597 | Kit 37200577, Diamondblack | |||
| 37200596 | Kit 37200578, Diamondblack | |||
| 37200607 | Kit 37200579, Diamondback | |||
| 37200606 | Kit 37200580, Diamondback | |||
| 37200605 | Kit 37200581, Diamondback | |||
| 37200604 | Kit 37200582, Diamondback | |||
| 37200603 | Kit 37200583, Diamondback | |||
| 37200602 | Kit 37200584, Diamondback | |||
| 37200600 | Kit 37200586, Diamondback | |||
| 37200595 | Kit 37200587, Diamondblack | |||
| 37200594 | Kit 37200588, Diamondblack | |||
| 37200591 | Kit 37200590, Diamondblack | |||
| 2 | 1 | O-ring | 11179 | |
| 3 | 1 | Clamp | 10076 | |
| 4 | 3 | Cable strap | 10039 | |
GENERAL
Models
For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.
Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets
Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.
Installation Requirements
Required separate purchase of a clutch release cover gasket.
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 the year and model motorcycle is required for this installation and is available from:
- A Harley-Davidson dealer.
- H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.
PREPARE
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 battery or remove main fuse. See service manual. |
REMOVE
Clutch Cable
| 1. | Record wire routing and cable strap locations before removal. a. Install new cable straps in the proper locations. | |
| 2. | Remove clutch cable. See service manual. | |
| 3. | If installing different handlebars, install now. See instructions provided in kit. a. Measure change in distance that is required from end of cable housing to clutch lever. |
WARNINGInstall 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)
| 4. | Compare additional required length to cable provided in kit. a. If cable is more than two inches (50.8 mm) longer or more than one inch (25.4 mm) shorter than above measured distance, see Harley-Davidson dealer for correct cable length. |
INSTALL
Clutch Cable
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.
Touring Models
| 1. | Apply a light coat of clean engine oil on new O-ring (2) before installing onto threaded portion of clutch cable end. | |
| 2. | Tighten clutch cable fitting to clutch release cover. Torque: 10–13 N·m (89–115 in-lbs) | |
| 3. | Replace stock grommet with grommet (6). | |
| 4. | After installation, follow instructions in Final Assembly and Clutch Cable Adjustment sections. | |
| 5. | Connect cable end to coupling (4). See service manual. a. Rotate ramps for best access. b. Install coupling on inner ramp. c. Place ramp assembly in position in clutch release cover. d. Install hand controls onto vehicle. See service manual. e. Install clutch cable onto hand control. See service manual. |
NOTE
- Do not install clutch cable prior to installing clutch perch.
Final Assembly
NOTE
- 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.
Cable Straps
NOTE
Accessory clutch cables are to be mounted and secured to the motorcycle in the same manner as Original Equipment (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.
Double-loop cable strap(s) (1) are included in kit to hold 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. a. Use one double-loop strap below adjuster to attach to frame tubes. | |
| 2. | Use a cable strap to secure clutch cable to handlebar and maintain cable routing. | |
| 3. | Figure 2 Wrap a cable strap (1) around downtube (2). a. Insert end into head (3) of cable strap. | |
| 4. | Figure 3 Wrap cable strap around clutch cable (2). a. Insert end into head of cable strap. b. Pull cable strap tight to secure clutch cable to downtube. c. Trim end of cable strap (3). d. Use remaining cable straps as necessary to provide clearance to vehicle. e. Verify free movement at steering lock to lock and no pinching of cable occurs, noting clearance between fork and clutch cable. Apply additional cable straps as necessary. Trim end of cable straps. | |
| 5. | Fill transmission with lubricant. See service manual. |
WARNINGBe 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)
| 6. | Connect battery cables, positive cable first or install main fuse. See service manual. |
| 1 | Cable strap |
| 2 | Downtube |
| 3 | Head of cable strap |
Figure 2. Install Cable Strap to Downtube
Clutch Cable Adjustment
NOTE
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. | Figure 4 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. See 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 clutch lever side of adjuster with one wrench while using the other wrench to rotate transmission end of adjuster. a. Twisting clutch lever side of adjuster could result in damage to the outer jacket of the clutch cable. | |
| 4. | When clutch adjustment has been completed, tighten jamnut against clutch lever side of adjuster. Tighten. Torque: 13.6 N·m (120 in-lbs) | |
| 5. | Verify clutch operation. See service manual. | |
| 6. | 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 3. 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 4. Clutch Cable Adjuster