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HARLEY DAVIDSON DIAMONDBACK "LE" CHROME SERIES CLUTCH CABLE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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CLUTCH CABLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery or main fuse following the instructions in the appropriate Service manual. 2. When performing cable disassembly procedures, make careful notes as to the existing cable routing and existing cable strap locations. New straps can be installed in the same locations. 3. Remove the clutch cable following the instructions in the appropriate Service Manual. 4. If installing different handlebars, install them now (refer to the appropriate handlebar instruction sheet) and measure the change in distance that will be required from the end of the cable housing to the clutch lever. Install proper length clutch cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00448b) 5. Compare the additional required length to the cable provided in your kit. If the cable is more than two inches (50.8 mm) longer or more than one inch (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. CLUTCH CABLE INSTALLATION Sportster and Softail Models Do not over-tighten clutch cable threaded end fitting. Use recommended torque values. Damage to threaded fitting can lead to loss of transmission fluid, which could result in loss of control and death or serious injury. (00449c) -J04568
NOTE Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty. 1. See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing the O-ring onto the threaded portion of the clutch cable end. 2. Install the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). 3. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet. FLTR Models with Fairing Lowers 1. See Figure 1. Carefully twist the clutch cable around the coiled opening in the clutch cable guide (2) with the eyelet toward the left handlebar. 2. Route the clutch cable assembly down from the clutch cable clamp while crossing to the right side of the vehicle. Run the cable between the inboard side of the right frame downtube and the outboard side of the voltage regulator. 3. The clutch cable clamp, mounted on the engine guard, has two fingers, an upper and a lower. Feed the cable assembly under one finger and over the other. 4. Finish the installation of the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). NOTE See Figure 2. Adjust the clutch cable clamp to 2.25 ± 0.25 in. (57.15 ± 6.35 mm) as measured from the inside lower left fairing mount to the clutch cable clamp. 5. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet.

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HARLEY DAVIDSON STAINLESS STEEL BRAIDED CLUTCH CABLE KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 21-03-2011

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REMOVE CLUTCH CABLE 1. See Figure 1. Loosen clutch adjuster to obtain slack in the clutch cable (2) by performing the following: a. Locate cable adjuster (1) and slide off rubber boot (4). b. While holding cable adjuster with 1/2-inch wrench, loosen jam nut (3) using a 9/16-inch wrench. c. Turn cable adjuster until there is a large amount of free play at hand lever. 1 2 3 4 is 00889 1. Cable adjuster (1/2-inch) 2. Cable end 3. Jam nut (9/16-inch) 4. Rubber boot Figure 1. Clutch Cable Adjuster 2. See Figure 2. Remove the retaining ring (1), pivot pin (2) and clutch cable anchor pin (3) from the hand lever. 2 3 1 is 00891 1. Retaining ring 2. Pivot pin 3. Clutch cable anchor pin Figure 2. Clutch Cable Compoments 3. See Figure 3. Drain transmission lubricant and remove fill plug dipstick. Remove the six screws that hold the clutch release cover in place. Remove the clutch release cover, being careful not to damage the gasket. NOTE The clutch release cover gasket (P/N 36801-87B) will need to be replaced if torn or damaged to prevent transmission fluid from leaking from the release cover. 4 3 5 2 6 1 is 00894 Figure 3. Clutch Release Cover Screw Sequence 4. See Figure 4. Note position of retaining ring opening. Retaining ring opening must be positioned in approximately the same location during reassembly. Remove retaining ring (1). 5 4 1 3 2 is 00895 1. Retaining ring 2. Inner ramp 3. Cable fitting 4. Clutch cable 5. Ramp coupling Figure 4. Clutch Cable Connection 5. Pull inner ramp (2) and coupling (5) out of side cover. Hold inner and outer ramps together to keep balls from falling free. 6. Rotate the inner ramp to a position that will allow the coupling (5) to be disconnected from the inner ramp lever arm. Disconnect coupling from inner ramp. Disconnect cable end from coupling. 7. Back out threaded cable fitting from side cover. Ensure that o-ring is removed with cable. Discard o-ring. INSTALL CLUTCH CABLE 1. See Figure 4. Obtain braided stainless steel clutch cable from kit. Apply a light coat of oil on new o-ring and install o-ring (Part Number 11179) onto threaded portion of clutch cable (4). Insert clutch cable fitting (3) into clutch release cover. Do not tighten cable fitting at this time. 2. Connect cable end to coupling. Rotate ramps for best access and install coupling on inner ramp. Place ramp assembly in position in side cover. 3. Install retaining ring. Position retaining ring opening so it is located approximately over the outer ramp tang (the stop that prevents rotation). NOTE Replace clutch release cover gasket if torn or damaged. 4. See Figure 3. Place gasket, if removed, on side cover and install side cover. Tighten the six screws in the order shown to 84-108 in-lbs (10-12 Nm) . 5. Tighten the clutch cable fitting to 36-60 in-lbs (4-7 Nm) . 6. Place a few drops of oil inside cable housing. 7. Route clutch cable as follows: SOFTAIL MODELS FXSTD, FLSTS, FXSTS and FXST – Route clutch cable from the clutch release cover, across the frame, up along the front frame downtubes and across the front of the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. FLSTF and FLSTC – Route clutch cable from the clutch release cover, across the frame and up along the front frame down- tubes, up to and behind the handlebars. Cable straps (item 1 in service parts illustration) to be used in same location as original equipment straps. DYNA MODELS FXDWG – Route clutch cable from the clutch release cover, under frame and across to the left side. See Figure 5. Insert cable (1) into clip (2) at the bottom left side of the frame

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HARLEY DAVIDSON FXD (Dyna Super Glide) TACHOMETER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 06-03-2011

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1995 Models To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1.1995 MODELS, REMOVAL OF ELECTRONIC SPEEDOMETER AND BRACKET 1a. Refer to applicable Service Manual procedure and remove seat. 1b. Refer to applicable Service Manual procedure and remove fuel tank. Stop the engine when refueling or servicing the fuel system. Do not smoke or allow open flame or sparks near gasoline. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00002a) 1c. Remove speedometer sensor cable from mounting clips under tank. See Figure 1. The 3-place speedometer sensor connector [65] is located on the frame beneath the seat. Remove connector from t-stud and disconnect. Cut cable tie holding sensor wires to right rear frame tube. 1d. Refer to applicable Service Manual procedure and remove headlamp, for work clearance. 1e Remove handlebar clamp screws securing speedometer bracket. Remove speedometer, bracket, and harness. 2.1995 MODELS, DISCONNECT MAIN WIRING HARNESS 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 2a. Disconnect the battery, negative cable first. Refer to applicable Service Manual procedure and disconnect main wiring harness 8-place connector [21A, B], at the front of the motorcycle. 3.1995 MODELS, REMOVE SPEEDOMETER LEADS FROM 8-PLACE CONNECTOR [21B, A] (FIGURE 2) 3a. See Figure 2 and Service Manual wiring schematic. Pull the following wires and terminals out of connector [21B]. Wire Color Cavity Number Orange/white 5 White/green 1 Black 2 3b. Remove the large female connector from the fuel gauge black wire. 3c. Slide the wires removed in step 2a out of the plastic conduit covering the wires connected to the 8-place connector. 1 WARNING 1 WARNING 1 WARNING Figure 1. Speedometer Sensor Connection [65] 4973 Speedometer sensor connector [65] Figure 2. Tachometer/Speedometer Wire Splices and Terminal Connections [21B, A] i00240-.tif Splices 4.1995 MODELS, REMOVE INDICATOR LAMPS FROM BRACKET 4a. Remove the screws that secure the indicator lamps assembly to the speedometer bracket. Retain screws and indicator lamps assembly for installation on speedometer/tachometer bracket later. 5.1995 MODELS, REMOVE SPEEDOMETER FROM BRACKET 5a. Unscrew boot from speedometer reset switch. Remove cover screws and rear cover. 5b. See Figure 3. Note position of rear speedometer gasket and remove it. Push on rear of speedometer while simultaneously pulling speedometer and front gasket from bracket. Do not remove front gasket from the speedometer. 6.1995 MODELS, INSTALL SPEEDOMETER IN KIT BRACKET 6a. See Figure 5. Place wires from speedometer through front of left opening in double bracket. Lubricate the front and rear gaskets with isopropyl alcohol or glass cleaner to ease installation. 6b. Insert speedometer into the front of the double bracket. Be sure wire guides are aligned with opening at bottom of bracket. 6c. Place rear gasket in position and align gasket tabs. Work gasket into space between speedometer and bracket by pushing speedometer against one side of bracket while pushing gasket into position at the opposite side. 6d. Add amber bulb assembly from kit to speedometer in order for tachometer and speedometer backlighting to match. 6e. Replace cover and boot from reset switch.

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KAWASAKI Z1000 GTR Electronic Cruise Control Installation Manual

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Filed Under (Kawasaki) by admin on 25-10-2010

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The actuator spool is installed in the CIU housing with the actuator cable. The actuator spool is rotated to fully extend the cable. 2nd step. The dual spool and carburettor cable are installed. The carburettor cable is attached to the lower groove in the dual spool. The other end of the carburettor cable is attached to the carburettors. Note the position of the roll pin. It is nearly contacting the end of the groove in the actuator spool. The free play in the carburettor cable must be adjusted so that the cable outer can be pulled out 2 ~ 3mm before the carburettors start to open. This ensures that the cruise control cannot prevent the carburettors returning to idle. If more free play is allowed the response of the cruise control is compromised. This adjustment of free play is usually performed after final assembly of the CIU is completed and the CIU is in its final location. This is because flexing the cable affects the free play. It is shown at this stage in these diagrams to improve clarity. After this adjustment is performed, the carburettor cable adjustment MUST NOT BE MOVED. All future adjustments of free play in the throttle must be performed on the throttle cable from the throttle grip. If incorrect free play in the carburettor cable is suspected due to inconsistent cruise operation or because of inconsistent idle speed, the adjusters on the throttle cable from the hand grip must be backed all the way off to give as much free play as possible. If this does not result in AT LEAST 5mm of free play in the throttle cable, the throttle cable must be removed from the hand grip or CIU before adjustment of the carburettor cable is attempted. This is crucial because the amount of free play in the throttle cable also affects the apparent free play in the carburettor cable

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HARLEY DAVIDSON TLE/TLE-ULTRA SIDECAR ATTACHMENT KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-03-2011

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REMOVAL NOTES Refer to the service manual for more information on these generalized steps. Save all removed parts (unless otherwise noted) for installation of this kit or for motorcycle operation without the sidecar. 1. For TLE-Ultra Models: Remove both lower fairings. 2. Remove the bolt and lockwasher securing the right passenger footrest bracket and remove the bracket with footrest. 3. Remove the three right side exhaust heat shields. Some models may require removal of the right side exhaust pipes. 4. Remove stock clutch cable. 5. Remove rear master cylinder/rear brake pedal assembly. Remove rear brake pedal from master cylinder assembly. Remove and save rubber pedal pad and brake pedal. Discard cotter pin. 6. Cut the cable straps holding front oxygen sensor connector to frame bracket. 7. Remove wire harness/brake line clip from right lower frame tube. INSTALLATION New Clutch Cable Installation 1. Refer to the service manual and follow instructions to remove stock clutch cable. 2. Refer to the service manual and follow instructions to connect the new clutch cable to clutch hand lever. 3. For FLHT/C/CU: Follow the instructions in the service manual to route new clutch cable through fairing. 4. For FLHR/C Models: Capture the cable in a clamp at the left upper passing lamp bolt. On FLTR models, capture the cable in a clamp at the left upper bolt securing the speedometer and tachometer housing to the upper fork bracket. These locations are identical with stock cable routing. 5. See Figure 1. Route clutch cable down along left frame downtube (1). 6. Continue to route cable down between left front engine isolator and crankcase. Clutch cable will cross to the right side of motorcycle beneath the crankcase, to the clutch release cover on the right side of the transmission. 7. Install clutch cable fitting into clutch release cover. Refer to the service manual. NOTES The final positioning and attachment of the clutch cable and clutch cable adjustment will be performed after sidecar mounts have been installed. Verify that the clutch cable and the rear brake line do not make contact. Damage could result. 1 2 3 is05785 1. Downtube 2. Clutch cable 3. Route clutch cable behind left front engine iso- lator Figure 1. Route Clutch Cable Relocating Oil Pressure Sending Unit NOTES Perform this procedure on all models equipped with an oil pressure gauge or Police models. All other models proceed to “Master Cylinder Assembly/Rear Brake Pedal Modification.” 1. Remove cable strap securing oil pressure wire harness to frame. 2. Locate the latch on connector to oil pressure sender (next to lower right frame downtube). Raise latch on connector and disconnect connector from oil pressure sender. 3. Remove the oil pressure sender using a 1-1/16 inch open- end crowfoot wrench. 4. See Figure 16. Coat threads of elbow (44) with Loctite 565 and install into crankcase oil pressure sender threads. 5. See Figure 2. Install elbow (1) until snug so open end is in the five-o’clock position (2). Do not over-tighten or crankcase may be damaged. 6. Coat threads of oil pressure sender with Loctite 565 and install into 90 degree brass elbow. Use a 1-1/16 inch open- end crowfoot and tighten to 96-120 in-lbs (11-14 Nm) . 7. Install connector on oil pressure sender unit. Verify that slight clearance to the right engine isolators is present. Adjust position of elbow as required to provide clearance

HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/IDLE CABLE KITS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 20-03-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be installed in the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3 2 1 is00825 1. Brake lever 2.5/32 inch (4 mm) cardboard insert 3. Brake lever bracket Figure 1. Install Cardboard Insert 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 3 4 1 2 5 is 02071 1. Upper switch housing 2. Lower switch housing 3. Throttle cable adjuster 4. Idle cable adjuster 5. Adjuster jam nut Figure 2. Handlebar Throttle Control 4. Remove the right upper and lower switch housing screws. 5. Loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw and flat washer. NOTE If possible, leave the friction shoe in place. The friction shoe is a loose-fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken. 6. See Figure 3. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings. 1 2 4 3 is 02072 1. Throttle cable 2. Idle cable 3. Brass ferrule 4. Notch Figure 3. Throttle/Idle Control Cables 7. Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Remove cables with retaining rings from switch housing. Apply a drop of light oil on the retaining ring, if necessary, to help in removal. NOTE If installing different handlebars, measure the change in distance that will be required from the end of the cable housing to the throttle grip. Compare this additional required length to the cables provided in the kit. If the cables are more than 2.0 inches (51 mm) longer or more than 1.0 inch (25 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. Install proper length throttle cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00396b) 8. Follow instructions in the applicable service manual and remove air cleaner and backplate.

HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/ IDLE CABLE KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be placed into the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 4. Remove the right upper and lower switch housing screws INSTALLATION Throttle and Idle Cable Installation 1. See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar. NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable. For assembly, apply a drop of light oil on the retaining rings of the crimped inserts. 2. See Figure 7. Push the throttle cable housing and retaining ring into the larger hole of the switch housing, located in front of the tension adjuster screw. 3. Push the idle cable housing and retaining ring into the smaller hole of the switch housing, located behind the tension adjuster screw. 4. Push the throttle and idle control cable housings into the lower switch housing until each snaps into place. NOTE For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw. 5. Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.12 inch (3.2 mm). 6. See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (Item 3, Figure 11) from this kit onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip. 7. Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar. 8. Tighten the upper and lower switch housing screws finger- tight. 9. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. 10. Align the holes in the handlebar clamp with those in the master cylinder housing and tighten the lower screw and flat washer finger-tight. Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm)

HARLEY DAVIDSON COMBINATION SPEEDOMETER/TACHOMETER GAUGE KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2011

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Removing the Old Speedometer NOTE This Instruction Sheet covers several different Harley- Davidson models and years. Make sure you locate and follow the procedures that apply to the motorcycle receiving the new gauge. 1. Apply power to motorcycle and record the odometer reading. 2. Remove the seat according to the procedure in the applicable Service Manual. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative cable first) before proceeding. (00048a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 2. Disconnect battery cables, negative cable first. NOTE Cover the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 3. Remove the instrument console acorn nut (and mounting screw with a flat washer on some models). Lay clean shop towels on the fuel tank. Lift the console from the fuel tank, turn it upside down and lay it on the towels. NOTE If necessary, bend back the flexible metal clip to free the harness conduit from the underside of the console. 4. Unplug the 12-terminal connector (39B) from the back of the speedometer. Depress the external latches and use a rocking motion to separate the pin and socket halves. 5. Remove the back clamp: All models except FXSTD: Gently pry the three latches upward to release the back clamp from the back of the speedometer. FXSTD: Depress the three external legs of the lock ring, then gently pry the three latches upward to release the back clamp from the back of the speedometer. 6. Unscrew the trip-meter reset button, and pull the harness from the clamp (remove the screw if necessary). 7. Lift the console and remove the old speedometer from the console. Discard the old speedometer, but retain the rubber gasket and back clamp for use with the new gauge. NOTE Set the console securely on the towel-covered fuel tank, and take care that it doesn’t fall off during the following opera- tions. 8. Set the console securelyon the fuel tank. Installation and Final Check NOTE Apply window cleaning fluid or mild soapy water to the speedometer gasket as needed to aid installation. 1. Turn the console over, facing upward. 2. Place the speedometer gasket into position around the console speedometer bore. 3. Fit the new gauge into the bore so that it fits snugly against the rubber gasket. Rotate the gauge into approximate visual alignment. The back clamp will complete the alignment. 4. Turn the console over, face down. 5. Install the back clamp

HARLEY DAVIDSON CLUTCH CABLE ASSEMBLY INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 05-03-2011

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36753-87A This kit fits 1987 and later FXLR model motorcycles. 36755-87A This kit fits 1987 and later FXRS/SP model motorcycles. 38601-89 This kit fits 1988 and later FLTC, FLTC-Ultra, FLHS, FLHTC FLHTC-Ultra and FLHTP model motorcycles. 38606-87A This kit fits 1987 and later FXR, FXRS and FXRT model motorcycles. 38607-87A This kit fits 1987 and later FLST, FXST, FXSTC, FXRP, FLTC, FLHT, FLHTP and FLHTC model motorcycles. 38617-95 This kit fits 1995 and later FXSTSB model motorcycles. 38647-98 This kit fits 1998 and 1999 FXSTB model motorcycles. 38661-00 This kit fits2000 and later FXDL, FXDS-CONV and FXDWG model motorcycles. 38664-00 This kit fits2000 and later FXSTD model motorcycles. 38665-00 This kit fits2000 and later FXSTB model motorcycles. 38666-00 This kit fits2000 and later FXSTS, FLSTS, FLSTC, FLSTF, FXDX, FXD and FXST model motorcycles. 38667-00 This kit fits 2000 and later FLTR, FLTRI, FLHT, FLHTC, FLHTCI, FLHTCUI, FLHR, FLHRI, FLHRCI and FLHP model motorcycles. 38672-01 This kit fits 2001 and later FXDWG2 model motorcycles. Kit Contents: QTY DESCRIPTION 1 O-ring, rubber 1 Cable, clutch 1 Pin, cable pivot 1 Grommet (Kit no. 38607-87A, 38660-00A and 38667-00 only) Installation NOTE A Service Manual for your motorcycle is available from your Harley-Davidson dealer. A SERVICE MANUAL IS NEEDED TO INSTALL 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. 1. Refer to the Service Manual for your motorcycle model. Screw the cable adjuster all the way in to allow for maximum cable free play. 2. Remove clutch hand lever from hand-lever bracket at pivot pin. Remove original clutch cable from hand lever and transmission. Retain anchor pin bushings. 3. See Figure 1. Install lever end of new clutch cable. Position cable eyelet in clutch lever slot. Retain with new cable pivot pin through original bushings. NOTE See Figure 2. When routing cable on models where clutch cable passes through inner fairing (FLHTC, FLHTC-U and FLHTP with fairing), clutch cable eyelet may be too large to pass through clutch cable access hole in fairing. If this is the case, use the template supplied with this sheet to file out a hole to accommodate the new eyelet. Place the grommet included with kit no. 38607-87A, 38660-00A, and 38667-00 in the hole after filing. 4. Secure the clutch lever in the lever bracket with the lever pivot pin and retaining ring. 5. Follow steps outlined in the applicable Service Manual and install the transmission-end of the new cable with O- ring. 6. Adjust clutch cable according to procedure in Service Manual.

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BMW K1100 RS/ RT/ LT ABS 2 Electronic Cruise Control Installation Manual

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Filed Under (BMW) by admin on 26-10-2010

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The actuator spool is installed in the CIU housing with the actuator cable. The actuator spool is rotated to fully extend the cable. 2nd step. The carburettor cable and spool are installed and the other end of the carburettor cable is attached to the carburettors. Note the position of the roll pin. It is nearly contacting the end of the groove in the actuator spool. The free play in the carburettor cable must be adjusted so that the cable outer can be pulled out 2 ~ 3mm before the carburettors start to open. This ensures that the cruise control cannot prevent the carburettors returning to idle. If more free play is allowed the response of the cruise control is compromised. This adjustment of free play is usually performed after final assembly of the CIU is completed and the CIU is in its final location. This is because flexing the cable does effect the free play. It is shown at this stage in these diagrams to improve clarity. After this adjustment is performed, the carburettor cable adjustment MUST NOT BE MOVED. All future adjustments of free play in the throttle must be performed on the throttle cable from the throttle grip. If incorrect free play in this cable is suspected due to inconsistent cruise operation or because of inconsistent idle speed, the adjusters on the throttle cable from the hand grip must be backed all the way off to give as much free play as possible. If this does not result in AT LEAST 5mm of free play in the throttle cable, the throttle cable must be removed from the hand grip or CIU before adjustment of the carburettor cable is attempted. This is crucial because the amount of free play in the throttle cable also effects the apparent free play in the carburettor cable.

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