M1544

M1544
2022-11-30
M1544: 2021 TOURING AND TRIKE MECHANICAL CLUTCH CABLE
Reason for Revision
Wrong Procedure
Refer to Table 1.
1.
See Figure 1. Do not use two hands to push-in lock button.
2.
Do not use any tools to push-in lock button.
Table 1. Document History
Date
Revision Description
2022-11-30 Initial release
1671055
Purpose for Service Bulletin
This bulletin informs dealers that Harley-Davidson has identified
the proper way to handle the cable during external free-play
adjustment and to secure the cable lock button.
Motorcycles Affected
1
2021 and Later CVO, Police, Touring and Trike models.
2
Markets Affected
All markets are affected.
Required Dealer Action
Table 2.
Action
Required
NO
YES
Resolution
Non-Actionable:
This is for informational purposes only or a technical tip.
1.
2.
Resolution
Lock button
Two fingers
Figure 1. Wrong Procedure
Correct Procedure
NOTE
The cable should only be removed and installed from the cable
retention clips when the cover is over the adjuster mechanism.
1.
See Figure 2. Use only one finger to push-in lock button.
2.
Only minimal effort is required to push-in lock button.
Make sure lock button is properly seated and secured into clutch
cable body.
3.
If excessive force is being used, stop and take a closer
look at the clutch cable/housing assembly.
NOTE
• There should be minimal effort to push in the lock button.
4.
Review procedures and pictures below to make sure button
is not being impeded.
• It should only take one finger to push in lock button.
• If excessive force is being used, stop and take a closer look
at the clutch cable/housing assembly.
• Review procedures and pictures below to make sure button
is not being impeded.
NOTE
In the interest of preserving customer safety and satisfaction, always check for outstanding recalls whenever any motorcycle is brought into your dealership for either maintenance or service.
ROUTING
INITIAL HERE
SERVICE
MANAGER
SALES MANAGER PARTS MANAGER
WARRANTY
PROCESS
MANAGER
LEAD TECHNICIAN TECHNICIAN NO. 1 TECHNICIAN NO. 2 TECHNICIAN NO. 3 RETURN THIS TO
1671057
1671056
2
1
1
1
2
1.
2.
Lock button tabs not fully engaged
End of upper clutch cable
Figure 3. Improperly Installed Button
1671058
1.
2.
Lock button
One finger
Figure 2. Correct Procedure
Improperly Installed Button
NOTE
Improperly installed lock button with tabs misaligned, tabs not
properly engaged or upper clutch cable interfering with the lock
button, is a sign of incorrect internal adjustment. See the service
manual for clutch adjustment.
1.
2.
3.
See Figure 3. Lock button tabs are not fully engaged (1)
because the end of the upper clutch cable (2) is interfering
with securing the button.
See Figure 4. The tabs on lock button tabs are not fully
secured.
a.
Lock button tabs partially engaged (1).
b.
Lock button tab not fully engaged (2).
1
1.
2.
2
Lock button tab partially engaged
Lock button tab not fully engaged
Figure 4. Improperly Installed Button
See Figure 5. A misaligned lock button (1, 3) is a sign of
an incorrect installation.
2/3
M1544
1671061
1671059
1
1
3
2
2
1.
2.
1.
2.
3.
Misaligned lock button
Clutch cable body
Misaligned lock button
Figure 5. Improperly Installed Button
Properly aligned lock button
Lock button tab fully engaged
Figure 7. Correctly Installed Button
1671062
6
Proper Button Engagement
1.
See Figure 6. Lock button tabs are fully engaged (2) to
clutch cable body (1).
2.
See Figure 7. A properly aligned lock button (1) should be
semi-flush with the rest of the cable clutch assembly.
3.
The lock button tabs should be fully engaged (2) to the
body.
4.
See Figure 8. Make sure the lock button (4) is installed
between the ends of upper clutch cable (1, 3).
1
5
2
1671060
1
4
3
1.
2.
3.
4.
5.
6.
End of upper clutch cable
Lock button tabs
End of upper clutch cable
Lock button
Clutch cable body
Upper clutch cable
Figure 8. Proper Button Engagement
2
2
1.
2.
M1544
Clutch cable body
Lock button tabs fully engaged
Figure 6. Correctly Installed Button
3/3