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Section 2: Assembly
STEP4: Install ForwardClutch Cable
1. Attach the forward clutch cable bracket (P,
Fig. 2-4) to the handlebar support (A) with a
1/4"-20 x 1-1/4" hex hd. screw (R, Fig. 2-4) and
1/4"-20 hex Iocknut (S). Tighten securely,
2. Carefully unwrap the forward clutch cable
(cable without a knob) from its shipping
position and slide the thin cable wire (T, Fig. 2-
4) into the slot in the cable bracket, Push the
cable connector (U, Fig. 2-4) up through the
hole in the bracket until the groove in the
connector snaps into place.
3. Insert the #10-24 x 2" slotted hd. screw (V,
Fig. 2-5) into the cable spring (W) until the
screw threads extend through the spring.
4. Thread the #10-24 hex nut (Z, Fig, 2-5)
halfway onto the screw (V),
5. Thread the screw into the cable adjuster (X).
6. Hook the cable spring (W, Fig. 2-6) into the
"V"-shaped bend in the Forward Clutch Bail (Y).
7. Checkfor correct tension on the forward
drive belt by taking two measurements of the
cable spring, as follows:
a. With the Forward Clutch Bail (Y, Fig. 2-6) in
an open (released) position, measure the
length of the cable spring (W) from the
outermost coil to the outermost coil,
b. Lift and hold the Forward Clutch Bail against
the handlebar (see Fig. 2-7) and re-measure
the length of the coils while the spring is
under tension. The belt tension is correct if
this second measurement is between 1/! 6"-
to- 3/16" longerthan the first measurement.
If so, turn the hex nut (Z, Fig. 2-7) tightly
against the cable adjuster (X) while prevent-
ing the adjuster from turning.
c. If the spring length is incorrect, you must
adjust the cable tension as described in
"Checking and Adjusting Forward Drive Belt
Tension" in Section 5. Incorrect tension on
the forward drive belt can result in belt
slippage (tension too loose) or un}ntentional
tine movement when the clutch bail is in
Neutral (tension too tight).
R
Fig. 2-4: Installing forward clutchcable bracket andcable.
w--[
Z--
V
X--
Fig.2-5:Assemble
springandadjuster.
Fig.2-6. Installforward clutchcable.
Fig. 2-7: To checkforward belt tension, take two measurementsof the
overall length of the coils in the spring- first with the clutch bail open,
then with the clutchbait closedagainst the handlebar.
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