Installed new bars, painted fairing, and Magnum Chromite II cables. All cables are the right length for the bars, but the problem is with the clutch cable. There isn't enough cable travel in the it. It's adjusted all the way out and it seems to be about an inch too short. I had to "pull" the cable to get enough to install the clutch handle into the cradle. Now it's loose for about 1/4 of the way to the grip and then it's engaging the clutch. Did I do something wrong? Or is there not enough travel in the cable? Need help asap.........

 

Recheck the routing, including where the cable ties hold the cable to the frame, and that the routing in the fairing is proper. Recheck where the cable hooks into the clutch release cover, and that the release parts are installed correctly. Did you adjust at the clutch pack on the primary side? If those things are all correct, then the length is not correct.

 

If it's like stock there are two adjustments. One by the clutch handle the other mid way down the frame down tube. On stock that mid way adjustment is in a rubber gater looking thing. That is the one you adjust the initial free play.

 

AHHHH NO! There is not one at the clutch handle!

If you changed the cable without doing the internal clutch adjustment on the primary side there lies your problem. Readjust the clutch according to the Service Manual and if that doesn't fix the problem then it will be the cable length itself.

 

My 2007 Ultra only had one place on the cable for adjustment, the one midway of the down tube with the rubber sleeve. There was no adjustment at the lever. You may need to double check where the inner cable hooks to the release mechanism inside the transmission side cover.

Another possibility is if you are not the original owner, someone may have put an aftermarket E-Z pull kit on it that has a short spacer on the end of the cable sleeve where it screws into the transmission cover. If the outer cable fits then the inner cable should be correct.

 

There is only one adjustment on the cable, midway down and its adjusted all the way out. I am the original owner of the bike, so no modifications done otherwise. I have not done the adjustment inside the primary yet, I hadn't really thought that would have this kind of affect on the cable. I will do that today. Thanks for the suggestions.

 

The length of the cable clutch has no bearing on the slack your seeing in the cable. In other words you can install a cable that's 10" longer than what you need and it will still work. Your adjustments are off. Put slack back in the cable, do your adjustment in the clutch pack, then adjust slack out of cable. If that doesn't take care of it then your problem is gonna be in the tranny cover. If you disassembled the ball and ramp to install new clutch cable, you may have reassembled it wrong.

2010 Limited with some stuff

 

Talk to Magnum asking them if your clutch cable is the correct application. If I remember correctly, there needs t o be a specific amount of 'pull' 3" comes to mind byt its been awhile.

 

Exactly. If I remember my install correctly, I had to pull a bit (not much) to get the lever installed in the perch, but everything adjusted correctly after that.

 

Just pulled the primary cover off and adjusted the clutch pack. Still have the cable adjusted all the way out (maximum slack) and it still only has half throw on the lever, will not go all the way to the grip before it starts to engage the clutch. I know for a fact that everything inside the tranny cover is correct as I checked and rechecked everything before reinstalling because I didn't want to have to pull it back off again. I'm trying to get ahold of the place I bought the cable from now, but no one is answering the phone.