THROTTLE KITS P/N 01-0343, P/N 01-0361 & P/N 01-0363posted Aug 31, 2009
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IMPORTANT - READ INSTRUCTIONS BEFORE INSTALLING
THIS KIT IS TO BE INSTALLED BY A TRAINED TECHNICIAN IN A PROPERLY EQUIPPED SHOP
THESE INSTRUCTIONS ARE FOR USE WITH TWIST GRIP TYPE THROTTLE KITS. THESE KITS ARE DESIGNED TO REPLACE THE ORIGINAL THUMB THROTTLE WITH A TWIST GRIP TYPE THROTTLE.
1. Remove the seat and fuel tank. Carefully observe how the stock throttle cable is routed from the thumb throttle to the carburetor. This is how you will want to route the new cable.
2. Temporarily remove any clamps or guides used to retain the throttle cable. Remove the stock thumb throttle assembly.
3. Throttle cable installation is different between the throttle kits listed above. Refer to the instructions below for your throttle kit.
THROTTLE KIT # 01-0343
Install the throttle cable onto the throttle cable bracket located on the carburetor. Screw the throttle cable adjuster all the way down onto the cable bracket. Install the cable end into the carburetor bell crank. Route the cable to the area where the throttle assembly will be mounted. Pull on the top cable end to make sure the full travel (up and down) of the throttle slide is smooth, without binding.
THROTTLE KIT # 01-0361
The original equipment throttle cable (1 into 2) is equipped with a junction box. Our kit is designed to replace the top cable only, utilizing the junction box and lower cables. Thoroughly clean the outside of the of the junction box. ANY DIRT OR FOREIGN MATERIAL THAT ENTERS THE JUNCTION BOX CAN CAUSE THE THROTTLE TO STICK. Remove the four screws and cover from the junction box. Disconnect the original equipment top cable and replace it with the cable supplied in the kit. Reinstall the cover and tighten the screws. Pull on the top cable end to make sure the full travel (up and down) of the throttle slide is smooth, without binding.
THROTTLE KIT # 01-0363
Thoroughly clean the outside of the carburetor. Remove the plate on the left side of the of the carburetor ( 6 screws). Do not allow any dirt or foreign material to enter the opening left in carburetor. ANY DIRT OR FOREIGN MATERIAL THAT ENTERS THE CARBURETOR CAN CAUSE THE THROTTLE SLIDE TO STICK. Remove the old cable and replace it with the cable supplied in the kit. Reinstall the plate making sure the "O" ring is in place. Tighten the side plate screws. Pull on the top cable end to make sure the full travel (up and down) of the throttle slide is smooth, without binding.
4. Remove the right hand grip from the handlebar. With the Allen wrench supplied, disassemble the new throttle assembly. Using the throttle sleeve as a guide, mark the handlebar showing where the sleeve will fit. With fine sandpaper remove any paint on the handlebar where the throttle sleeve will fit. IT IS VERY IMPORTANT THAT THE HANDLEBAR BE CLEAN AND SMOOTH. IF THE HANDLEBAR IS NOT CLEAN AND SMOOTH IT IS POSSIBLE FOR THE THROTTLE TO STICK.
5. Slide the throttle sleeve onto the handlebar. Loosen the small set screw and remove the split collet from the lower throttle housing. This collet is not used. Next, install the cable through the lower half of the throttle housing. Connect the cable end to the throttle sleeve slot closet to the grip. Assemble the upper and lower throttle housings while positioning the throttle sleeve stop above the housing stop. Allow an 1/8 inch clearance between the grip and handlebar end. This will prevent the grip from binding on the end of the handlebar. Position the throttle so that the throttle cable is routed correctly. Insert the throttle housing screws and tighten. Tighten the set screw into the groove on the throttle cable elbow.
6. Throttle cable adjustment: ALL THROTTLE CABLE ADJUSTMENTS ARE DONE WITH THE ENGINE OFF. Adjust the throttle cable so there is a slight amount of free play (1/16 to 1/8 inch). Tighten all adjuster nuts. Reinstall all cable clamps and guides. Check that the throttle will snap back from the full open position in all handlebar steering positions. Also, check that the cable has free play when the handlebars are turned side to side. Note: Cable routing and throttle position affect the smoothness of throttle operation. Route the cable to avoid sharp bends or kinks. Position the throttle so that it does not create sharp bends or kinks in the cable.
7. Install the fuel tank and seat. Start the engine to check throttle operation. Using throttle, raise engine speed momentarily to 4000 RPM and release throttle. Engine speed should drop quickly to idle speed without hesitation. Next, while turning the handlebars side to side, there should be no change in engine speed. Repeat, Step 8 if throttle is not operating as described above.
8. It is suggested that you familiarize yourself with the operation of the twist grip throttle. Run the machine at different speeds until you are completely familiar with how the throttle operates. If you have experience riding motorcycles the twist throttle will be quite natural. If you have only used the thumb type throttle you should practice until operation of throttle is done without second thought.