Motorcycle Repair: 01 FXDWG Clutch Cable, clutch cable, friction pads


Question
Just changed my buddies 01 WG clutch cable after 127,000 miles on it. Had a hole so it was leaking. Here is the problem, picked up new cable from HD Dealer correctly marked for this bike. No clutch problems before we changed cable. Now when we try to get it into gear we can't due to the fact the clutch is not disengaging enough. Ok, re-checked our work with manual and everything to include the 3 balls are place properly. All pieces move freely. You can pull the clutch inspection cover off and see clutch moving in and out. Tried adjusting cable, and now with it adjusted far enough to disengage the clutch will not engage when lever released. We inspected the clutch being it's original with a 127,000 miles on it but it appears to look fine, all friction pads are still in place and press plate spring is still good with no cracks, and plates appear to have no excessive wear. Everything worked till we replaced the cable and we have re-checked everything using the manual 4 times. Any ideas?

Answer
Before adjusting the cable at he clutch, loosen the cable all the way so you have plenty of slack in it. Now push the cable inward towards the trans so the ramp is all the way open. Now adjust the cable at the clutch and then the cable.
Good luck and happy riding
Mike