Wondering if anyone has a clue what could be wrong... Exteding the cables for apes on my 03 Nightrain. Replaced the clutch cable and now its only moving like 1cm when i pull the clutch in. I opened the case back up and tried moving the cable inside the housing and it seems it's a bit jammed and only fully enages if i tug on the wire  like 5-6 times. Im pretty sure the balls are in place too. Wondering could it be because i havnt filled the case with oil yet or that wont make a difference ??.. Does it matter where the snap ring is positioned ?? Any help much appreciated.

Ok after a play around i have the cable moving freely but now the lever pulls in but doesn't return back out...Theres no spring in the lever...I removed the level and i can pull the cable but it doesnt return back. Anyone know what this means...Can't work it out. Watched 10+ youtube vids and countless google pages haha

 

no spring it returns by the pressure plate spring pressure, no oil wont do anything, yes circlip does have to be in a set spot evo anyway buy memory
have you adjusted the cable at the adjuster half way along the cable 1/8 freeplay approx. at the lever maybe look at the balls/ramps again to

I would start from scratch.

Keep cable conected to lever.

loosen adjusting nut all the way, the one half way down your cable.

inspect where the cabe attaches to clutch and make sure its loose.

check the adjustment on the clutch itself. Left on the nut until it binds then 1/4 turn right.

take up all the slack again with the adjusting nuts, again, the one half way down your cable. As the cable gets shorter the sleck in the lever gets less.

Keep a small bit of free play at the lever end.

http://youtu.be/lWTESN1mLbY

I know the link is for a sporty but the theory should be the same.

 

If you have the right length cable for your new bars , and , the cable is adjusted within spec at the lever, and, clutch is adjusted within spec behind derby cover, and , cable is connected correctly in gearbox side, I can only think of one area where your having the symtoms your describing . Gotta be your balls !!! Check the ball / ramp area for proper installation as mentioned above !!!! Also , as mentioned above, the circlip has to be positioned a particular way. ie, the opening of the circlip to be inline with with an opening on the clutch release cover. Google , How to remove the clutch cable on a Harley Davidson big twin motorcycle . This video explains everything in detail . This guys videos has helped me a lot. Hope you sort the problem out , Cheers .

Thanks for the input so far guys. I've got the circlip in right spot and balls are in place. When i pull the cable it doesn't pull back to original position when ive got the derby cover off ??? The balls dont seem to be äcting as a spring. Ive played with adjusting nut and nothing although haven't touched the adjustments at clutch itself....The umbrella drive spins freely left and right and doesn't push in although i can pull it out. I thought that might of had some type of spring action in it as it gets pushed in by the inner ramp mechanisim....

Had a play today and i see how the balls work as a "spring" pushing the ramp and cable back to original position when the ramp has resistance on it. Only thing is when i put the derby cover on it doesn't want to work and the cable only has limited range of movement....

have a look at rob dawgs clutch post that's how you adjust the clutch

 

just re read your first post if the bike was working fine before you swapeed out the cable than you should not  have to  touch

the clutch basket ajustment , just the cable

Another candidate for purchasing a manual.

I don't know what happened but I left it overnight, came back to it the next day and now it works ??? I wouldn't be able to do anything without the service manual lol

Very strange indeed.