I'm getting ready to install the Chrome Primary Cover Trim (part 25233-04) on my 05 1200 Xl. It's the chrome second skin to spiff up the engine. The instructions have me taking off the lower end of the clutch cable then taking off the upper end and even the clips that hold the cable to the frame. I then put the primary cover on and reconnect the clutch cable. I've looked the instructions over a dozen times and I still can't figure out why I'd have to take the whole cable off when I'm just working on the lower end. I realize this could be a dumb question.... :rolleyes:

You need to free up the cable to be able to remove and re-install, it's a stiff bugger and you don't want to make to severe a bend in it, may cause damage.
It'll be much easier to thread the cable in and out of the case with the top end removed also.

Thanks Radar, that makes sense. I'll get started on it. :)

I just did this about a month ago. Tip: drain the oil from the primary before you start. I too thought I could get away with just disconnecting the top part of the cable. Halfway through the job I found out there is no way of getting this cover on without undoing the bottom part of the cable as soon as I unscrewed the cable out of the primary cover oil will start pouring out of the hole.

After I cleaned up the terrible oil mess on the garage floor I had the hardest time trying to get the threads started on the clutch cable/primary cover. The threads are very fine.

Good luck.

I did this same job two weeks ago. I didn't get covered in Tranny fluid, but I found out the hard way that you have to remove both ends of the clutch cable, otherwise it's a devil of a job to unscrew it from the gearbox housing.
(Initially I thought WTF - why both ends?)
Give it a go - it looks really good when finished!
The Brit

Thanks all! I'm closer to getting started on it....

I just did my 04 also. I put a board under kick stand to keep bike more upright. No fluid ran out. Be careful of the little gasket around inside of cover. Mine popped out and didn't want to stay in after that.

I'm about to start the same job on my 06 Sporty. Are there any special tools needed to remove the clutch cable lower end? I was going to start it yesterday but decided to wait because I wasn't totally sure on how to disconnect the lower cable.