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Keep & Kill
Last Post: Crusty
Posted On: 2 Hours Ago
Replies: 29,265
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25th January 2022
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Greasemonkey
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Join Date: Aug 2019
Posts: 148 Sportster/Buell Model: XLCH Sportster/Buell Year: 1972 Sportster/Buell Model #2: XL1200CX Sportster/Buell Year #2: 2019 Other Motorcycle Model: FXFBS Other Motorcycle Year: 2021
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Alternative to stock clutch cable?
I spent a decent chunk of change on some matching aftermarket clutch and brake levers. However, the metal grommet at the end of the clutch cable (I think P/N 38654-71) doesn't fit into the lever because the OD of the grommet is too large. I have a 1972 XLCH clutch cable right now.
Does anyone know of any alternative clutch cables that have smaller grommet ODs for a 1972 XLCH? I saw that the early XLCH cables have a different grommet (38654-53) but just by pictures it doesn't look much smaller and I'm not sure it would work.
My only other option I think is to drill out the lever to accept the 1972 clutch cable, but I don't know how I'd get a good fit seeing as I only have a power drill.
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25th January 2022
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XL FORUM TEAM MEMBER
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Join Date: May 2013
Location: East Midlands UK
Posts: 1,885 Sportster/Buell Model: XLCH Sportster/Buell Year: 1976 Sportster/Buell Model #2: XLCH Sportster/Buell Year #2: 74/5
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How much too big is the grommet? If just a little you could file a little off to reduce the OD. I did that on my project as I had the same issue.
Paul
Sent from my iPhone using Tapatalk
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25th January 2022
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XL FORUM TEAM MEMBER
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Join Date: Dec 2011
Posts: 658 Sportster/Buell Model: XLCH Sportster/Buell Year: 1969 Other Motorcycle Model: FXE Superglide Other Motorcycle Year: 1976
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Barnett will make anything you want, give them a call.
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26th January 2022
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XL FORUM TEAM MEMBER
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Join Date: Feb 2010
Location: Webster, NY
Posts: 4,573 Sportster/Buell Model: XL 883/1200 Hugger Sportster/Buell Year: 1995 Sportster/Buell Model #2: 11 RK
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Magnum Shielding has some nice cables. Call them and they will custom make whatever cable you need.
https://www.magnumshielding.com/
__________________
...Once in a while you get shown the light, in the strangest of places if you look at it right...~Robert Hunter/Jerry Garcia
 (In remembrance of Ruby Red "Beebe")
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26th January 2022
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XL FORUM TEAM MEMBER
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Join Date: Jun 2008
Location: On a big rock in the Florida Straights
Posts: 432 Sportster/Buell Model: XLH 1200 S Sportster/Buell Year: 1999 Sportster/Buell Model #2: XR-1000 Sportster/Buell Year #2: 83 Other Motorcycle Model: RZV500R/R1 hybrid Other Motorcycle Year: 1984
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I have a hydraulic setup for my 83 XR... uses a 11/16 VROD master and one of these gizmoz:
https://www.billetproofdesign.com/hy...d-made-in-usa/
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1999 XL 1200 Sport RX, SE 7500 ignition, SE air filter, DynoJet, K&N, Cone Engineering 2:1 pipe, Storz Steering damper, with 2012 XR1200X perf forks, 3.5 x18" wheels front and rear, Galfer stainless lines, XR1200 4 piston front calipers, 18" dunlop trailmax mission 120/90 and 140/80 rear XR1200X perf shocks with 1" lift blocks...
1983 XR-1000S to XR-1000RX Project Build Thread
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