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Author Message   Juggalo080 Posted on Tuesday, February 28, 2006 - 08:48 pm:        Hey, I have an oil leak coming out of the primary cover where the clutch cable goes in. I have an 03 9S. I tried tightening the cable down a little more and that didn't help. I am wondering what there is for a seal where the cable goes in? I don't have a service manual and have not tried taking things apart yet. What has to be taken apart to change the seal? If the primary cover has to come off I probably need a quart of oil to go back into that as well as a primary gasket and also a shifter shaft seal correct? If someone has part numbers for these it would be appreciated. Thanks   Donutclub Posted on Tuesday, February 28, 2006 - 08:53 pm:        I had the same issue. Replace the clutch cable and it will solve your problem.   Jackbequick Posted on Tuesday, February 28, 2006 - 09:20 pm:        On the tubers there is an O-ring around the threaded shank on the cable housing that screws into the primary cover. The O-ring gets trapped between a shoulder on the theaded shank on the cable housing and the primary cover and provides the oil seal. When fitting that, you just want to take it down snug enough to trap the O-ring and get a seal. The cable housing can't really rotate and come loose because of the way it is curved. Jack   Whodom Posted on Tuesday, February 28, 2006 - 09:29 pm:        Also be aware that the threaded metal fitting on the end of the clutch cable sheath that screws into the primary is made of aluminum, and if you tighten it too much it will snap right off so easily it will scare you. Whether you replace the whole cable or just the O-ring, take it REAL easy when you tighten it into the primary cover.   Coturi Posted on Wednesday, March 01, 2006 - 12:10 am:        You can replace the seal or the whole cable by removing the inspection cover. You don't have to pull the primary cover. You will however need to replace the inspection cover gasket, its only a few bucks. I have to do mine soon as well, not a big deal at all.   Truk Posted on Wednesday, March 01, 2006 - 09:07 am:        I had the same problem and replaced the clutch cable and that fixed it. Simple job...the service manual explains how   Jackbequick Posted on Wednesday, March 01, 2006 - 04:17 pm:        Good follow up post Whodom! I had forgotten about that being aluminum. Jack   Whodom Posted on Wednesday, March 01, 2006 - 05:15 pm:        I had forgotten about that being aluminum. Glad to contribute. Ask me know how I know about it being made of aluminum and being VERY easy to wring off...   Sik_s Posted on Wednesday, March 01, 2006 - 05:36 pm:        Anybody have a page number for changing the clutch cable out of the service manual for the XB. I looked under "clutch cable" and it isn't listed in the back.   Coturi Posted on Wednesday, March 01, 2006 - 07:21 pm:        Page 2-66 for an 05 Lightning book.   Sik_s Posted on Wednesday, March 01, 2006 - 07:59 pm:        Thank you very much (that is the same for my '04 firebolt manual), I am blind apparently. This head cold is killing me, thanks again kind sir.   Juggalo080 Posted on Friday, March 03, 2006 - 10:11 am:        Thanks for the info, I will change the clutch cable and get a gasket for the cover, anyone know the prices on these pieces?   Sik_s Posted on Friday, March 03, 2006 - 10:22 am:        I just got one from Daves for around 25.   Chadhargis Posted on Friday, March 03, 2006 - 12:55 pm:        I've got 1500 miles on my Ulysses and noticed a bit of weeping. Not really a leak, just some oily residue. I elected to not do anything. It's not bad enough to fool with, but it's nice knowing there is a seal back there.   Sik_s Posted on Thursday, March 23, 2006 - 03:12 am:        I finally got all the parts. I looked in the service manual, and it just says to route the clutch cable to the primary. How much torque do I use to tighten the fitting into the primary? I imagine the o-ring goes on the fitting that attaches to the primary there (manual doesn't explain or show this). What torque do I use on the wireform that holds the cable away from the exhaust header? As always, any help is appreciated.   Jackbequick Posted on Thursday, March 23, 2006 - 01:26 pm:        If that is the same as the tuber clutch cables, that fitting on the on the primary end is aluminum. The SM calls for 3-5 foot pounds and that is a dumb way to specify it. I would think of it as 36-60 in/lbs and I would go for 30 in/lb or even less as a start. If I felt it was snugging down and the O-ring partially deformed, I would quit there. The threaded shank on that fitting is known to be VERY EASY TO BREAK OFF in the course of trying to get it as tight as you might think it needs to be. With the normal curves in the cable, and the adjuster lock nutted, that fitting probably can't rotate itself loose anyway. You can test that by trying to rotate it. I don't have the torque specs for that wireform. You manual may have some general torque specs in the Appendix (mine does) so you could look up the fastener size if nothing else. Jack

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