Harley-Davidson 38662-00 - Manual

INSTRUCTIONS
-J00087 REV. 07-26-03
CLUTCH CABLE KIT
®
General
Kit 38620-96 is designed for installation on:
• 1996 through 1999 XLH Sportster ® 883 Hugger,
• 1996 through 1999 XLH Sportster 1200, and
• 1996 through 1999 XL 1200C Sportster Custom.
Kit 38662-00 is designed for installation on:
• 2000 through 2003 XLH Sportster 883 Hugger, and
• 2000 through 2003 XLH Sportster 1200.
Kit 38663-00 is designed for installation on:
• 2000 through 2003 XLH Sportster 883,
• 2000 through 2003 XL 883C Sportster Custom,
• 2000 through 2003 XL 1200C,
• 2000 through 2003 Sportster 1200 Custom, and
• 2000 through 2003 XL 1200S Sportster Sport.
See the Service Parts illustration for kit contents.
A Service Manual is necessary for installation of this kit.
The rider's safety depends upon the correct installation
of this kit. If the procedure is not within your capabilities
or you do not have the correct tools, have your Harley-
Davidson dealer perform the installation. Improper
installation of this kit could result in death or serious
injury.
NOTE
A Service Manual for your model motorcycle is available
from any Harley-Davidson dealer.
Installation
To prevent accidental vehicle start-up, which could
cause death or serious injury, disconnect negative (-)
battery cable before proceeding. (00048a)
1. Refer to the Service Manual and follow the instructions
given to remove the seat and disconnect the negative
battery cable. Retain all seat mounting hardware.
NOTE
Before removing clutch cable, make careful note of the
existing cable routing. Pay special attention to existing cable
strap locations before removing so new straps can be
placed into the same locations.
2. Refer to CLUTCH CONTROL, REMOVAL in the
Service Manual to remove the old clutch cable.
3. See CLUTCH CONTROL, INSTALLATION in the
Service Manual to install the new clutch cable.
4. Adjust the clutch cable according to the procedures in
the Service Manual.
5. Refer to the Service Manual and follow the instructions
given to re-attach the negative battery cable and install
the seat.
1
WARNING
1
WARNING
Service Parts
® Clutch Cable Kit
Date 07/03 Part No. 38620-96 & others
ITEM DESCRIPTION PART NO.
1 Clutch cable (incl. boot) Not sold separately
2 Boot 38630-88
3 Pin, clutch cable 45036-88
Eyelet
“O”-ring
1
3
Hand lever
2
sp38619
Kit Number 38620-96, 38662-00 and 38663-00