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Author Message   Boisexb12 Posted on Saturday, February 04, 2012 - 02:29 pm:        I replaced the clutch cable on my '04 xb12 using the guidelines in the manual. 1. I have no "spring" in my clutch handle. After i pull it in it does not return to the out position. 2. Even though the bike is in neutral the clutch handle will "buck" along with the engine if i try to start the bike and I also hear a combo catching/grinding noise. 3. Looking at the clutch with the inspection plate removed, everything seems to be in order. with the plate removed I can see the cable pull and return the lever in the clutch when i pull in and push out the clutch handle. If you have any ideas please help. I'm not to interested in dropping my bike and tax return off at the local H.D. shop.   Danair Posted on Saturday, February 04, 2012 - 06:13 pm:        Did you adjust the actuator that the cable attaches to and then adjust the cable? (Message edited by danair on February 04, 2012)   Sticks Posted on Saturday, February 04, 2012 - 06:27 pm:        Does it need to be lubricated? I'm going to need to do a new clutch cable too as the outer cover is cracked where it contacted the chin fairing. Never done it before, so curious.   Boisexb12 Posted on Sunday, February 05, 2012 - 12:40 pm:        No the new cable shouldn't need lubricated. there is a great DIY video on a different site, buellxb.com. Yes i adjusted everything, but i do think that i had it way too tight at the beginning. just for kicks i did the entire install over again but with the same result. i think i may have broke something in the clutch or transmission.   Akbuell Posted on Sunday, February 05, 2012 - 01:56 pm:        Check the 'ears' that are around the upper 2/3rds of the clutch inspection cover opening. Sometimes they crack and make the clutch lever wonky. The release mechanism doesn't have anything to push against. There is a thread somewhere in the archives about the issue, and how to fix it. Hope this helps, could be a possibility Dave   Teeps Posted on Sunday, February 05, 2012 - 07:29 pm:        Here's the link mentioned above: http://www.badweatherbikers.com/buell/messages/384 2/282980.html   Akbuell Posted on Sunday, February 05, 2012 - 07:54 pm:        Thank you, Teeps !!!   Boisexb12 Posted on Sunday, February 05, 2012 - 10:57 pm:        Thanks, for help everyone. Unfortunately I believe I'm going to have to bite the proverbial bullet.   Tbolt_pilot Posted on Tuesday, February 07, 2012 - 06:06 pm:        I put a new cable on last year and found it takes some fiddling to get it adjusted right. Just don't drop that little piece into the case! Don't ask me how I know. It sounds like you might not have enough 'pre-load' in the clutch and the handle is only bringing the spring up to contact the plates. (Someone correct my terminology if it's wrong) From experience, it's a fine line between too much or not enough with the clutch and the cable adjustment. I'd go back over your procedure. And check the cases very closely.

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