2005 Harley Davidson FLHT - FLHTI Electra Glide Standard Logo
Posted on Oct 19, 2009
Answered by a Fixya Expert

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Clutch cable leeks oil

At 11,000 miles my clutch cable was oil soaked, was told transmission was overfilled. now at 37.000 miles the same thing, changed oring where cable enerrs transmission

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  • Master 4,565 Answers
  • Posted on Oct 20, 2009
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Joined: Sep 22, 2009
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The o-ring around the threaded end where it enters the transmission only keeps the oil from leaking to the outside. If you're getting oil on the inside of your cable, the cable needs replacing. The small oil seal is in the end of the threaded piece that screws into the transmission end cover.

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The automatic transmission fitted on these models could be the AW-70, AW-70L or AW-72. The three transmissions are very similar. They are conventional in design though they are clutch-type (no brake bands) and very sturdy.
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The oil should be flushed out, filter changed and magnets cleaned at least every 80,000 miles. Have this done first to see if the problem goes away. If it persists, then the clutch pack for that gear or the valve body is suspect. If the oil is new and proper drain and flush procedures have been followed, it's possible that the check ball in the valve body is sticking once warm. What I have done with these is drop out that valve body and clean it thoroughly, provided scrupulous cleanliness is observed. While cleaning it, replace the check balls and associated springs. If this checks out OK after the maintenance, then it's possible the pistons, accumulators or clutch packs have probably worn out.

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One thing that causes the clutch to slip is overfilling the gearbox. The level should be at the BOTTOM of the filler hole threads. More than that can cause oil to run down the clutch release rod. Once it is oil soaked, there is little you can do.
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There are a couple of things that could cause your bike to be hard to get into first gear. One, cold oil. If this is only a problem when the engine is cold, the oil in the transmission is cold and thicker causing the gears in the transmission to have more force against them.

Two, too much oil in the primary case. This makes the clutch drag as it acts very much like the torque converter in an automatic transmission.

Three, the clutch may need to be adjusted. Find the rubber bellows in your clutch cable and slide it up or down to expose the cable adjuster. Loosen the lock nut and adjust the adjuster inwards to get a lot of slack in the cable.

Remove the derby cover on your primary. Loosen the locknut on the adjuster in the center of the clutch assembly. Turn the center screw inwards until you feel the resistance. Do not force the screw. Just turn it until you feel the resistance. Then, back it back out 1/2 turn. Lock the lock nut.

Go back to the cable adjuster and adjust it outwards until you have 1/8" freeplay in the cable. Lock the locknut and replace the rubber bellows.

Check the oil level in the primary. Stand the bike straight up. Look at the clutch inside the primary. The outer clutch hub is made of shiny aluminum with a darker or black "plate" inside of it. The black "Plate" is the spring. The oil should be no higher than the lower point of this plate. If overfilled, remove the drain plug on the bottom of the primary and drain a little of the oil out. Replace the derby cover.

If this does not fix your problem, the shifter pawl may be out of adjustment. I would recommend that you take it to your dealer to get this done. It is a delicate adjustment that requires special tools.

good luck
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Make sure you do not overfill the primary. when putting the oil in the primary, have the bikes standing as straight up as possible. Add oil only until it comes to the bottom of the clutch spring. If you put too much oil in the primary, the oil will get in between the plates when the clutch is released and act like the oil in a automatic transmission torque converter. It will continue to drive just enough so that you cannot find neutral with the engine running.

Otherwise, you must make sure all clutch adjustments are correct. Loosen clutch cable all the way. Adjust clutch release adjuster behind derby cover, all the way in and back off one half to one complete turn, readjust cable for 1/8" freeplay.
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It is possible, but really depends on how the bike was treated for those 11K miles. One thing you should check is that the clutch cable is properly adjusted. There should be some free-play at the clutch lever - see the owner's manual, but the first 1/4" or so of clutch lever movement should do nothing except take up slack out of the cable. Insufficient free play at the lever will cause the clutch to not engage fully, and slip.
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