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Rubber Mount Sportster Motorcycle Talk (2004-2006) This area is to discuss issues, problems and anything else unique to the 2004 and above Sportster motorcycles

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cable, clutch, leak, oil

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  #1  
Old 18th July 2021
krono's Avatar
krono krono is offline
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Smile Oil leaks and too long clutch cable

Well, I recently bought my third Sportster: 2005 XL 883 L in very bad condition, it was out of order under some sheets.

The thing is that, among the infinity of problems it has, I found that they have put a clutch cable much longer than the one it should carry (brake and accelerator line are standard length, I discard ape hangers, it has stock controls, they simply put what they found, is like 160 cm long, and should be 140 cm? 62" vs 55", I measured using a cord).

Is there a way to cut this cable to normal length that I can do at home with hand tools?

And the biggest problem I have: is losing oil, but not in the connection to the primary case, the oil is "rising" and leaving the regulation zone in the middle of the cable (check picture below).

I already cleaned it and verified that it is not cable lubrication, or retained water, but rather primary oil.

What I can do to solve the leak? I would like to shorten the cable I already have because I'm not at USA and this is very expensive here.


Check this picture : https://i.postimg.cc/MZ7RsvZV/imagen.png





Thanks
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  #2  
Old 18th July 2021
Andy56 Andy56 is offline
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Can you move the position of the slack to the lever end and move the adjuster up as high as possible? The cable supposed to be supported by clips either side of the adjuster. Maybe being in line with the ferrule the oil is traveling up the cable.

The easiest end I would think if you were to shorten the cable would be at the primary end but then you would still have the problem of where the adjuster is going to sit.
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  #3  
Old 18th July 2021
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Route the cable across the top tree, to the right side of the fork, and then back to the left side. That will raise the adjuster up enough to allow the primary oil to stay inside the case. The reason it's leaking at all is that the cable is running down from the case. If the cable is routed so that when it exits the case, it is rising, instead of sagging down below frame level, the oil will tend to drain back into the case, instead of following gravity down the cable. Had the same problem with the cable being too long when we swapped a set of Custom bars onto my wife's Low to get rid of the buckhorn bars. Hope this helps.
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  #4  
Old 30th July 2021
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Quote:
Maybe being in line with the ferrule the oil is traveling up the cable.
This was the source of the oil leak, thanks!

Quote:
Route the cable across the top tree, to the right side of the fork, and then back to the left side
This solved the problem, thanks!!

I post a image of what I did to help others, I re routed the cable like the red path, up, behind the fork, then curved left, hope this is OK, I tested it and seemed to be working fine...

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Old 30th July 2021
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Good fer you!
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