Illus 15 Steering Damper Assembly

Servicing Handlebar Controls

To lubricate control parts, or to replace a throttle or spark control wire, or a damaged control wire housing, proceed as follows:

Insert a large heavy screwdriver through hole in end of grip and turn out end nut by using a wrench on screwdriver. Sometimes this nut is difficult to remove. In this case, insert a punch into slot in nut and strike it two or three sharp blows to start it. After removing grip spiral, working parts are accessible. Remove plain roller, roller block, and roller pin. Disconnect control wire at carburetor or timer. Plunger, with control wire attached can now be removed. Wire is fastened into end of plunger by means of a hexagon head screw with a hole through it.

If control wire housing is to be removed, first remove above named parts. Next, remove the small set screw underneath handlebar, just ahead of spiral locating shoulder on bar (on left bar, this screw is under headlamp dimmer switch). Control wire housing can now be pushed out through end of bar.

When reassembling control parts to handlebars, apply a light coat of grease or a few drops of engine oil to control wire as it is inserted into control housing, and lubricate remaining parts with grease (See "Lubrication Chart," Page 15). Overgreasing of these parts will cause a messy condition around bars.

Grip spiral nut can best be started, without danger of crossing threads, by holding spiral back with slight pressure against nut while starting nut with screwdriver. In this manner, shoulder on nut is held squarely against end of spiral sleeve. Always tighten nut securely.

After handlebars and controls are completely assembled, connect control wires at carburetor and timer. Adjust controls so throttle closes and opens fully with carburetor control grip movement and so timer fully advances when its control grip is turned to inward position.

Replacing Front Brake Control Wire

Remove control wire lower clevis clamp nut and pull wire out of clevis. Next, remove cotter pin and flat washer from handlever hollow pin and pull pin out of lever. Control wire can now be pulled out through pin hole in handlever.

Insert new control wire, reversing procedure in which old wire was removed. Apply grease or engine oil to new wire as it is being inserted'. Handlever hollow pin must be reassembled before lower end of wire is connected. Narrow slot in pin straddles wire. Replace flat washer and cotter pin at end of hollow pin.

Adjust wire housing to nearly maximum slack by turning adjusting sleeve (Detail 27, Page 10) almost through the boss into which it is threaded. Insert end of wire through clevis nut, then through hole in clevis and back through clamp nut again. Pull wire snug through clevis and secure by tightening clevis nut. Excess wire can be cut off.

Adjust control, by means of adjusting sleeve, so that handlever moves freely about one-quarter of its full range of movement before brake begins to take effect. Tighten adjusting sleeve lock nut.

Servicing Saddle Sprii.g Post

Illustration shows following parts of spring seat post assembly:

1. Spring tension adjusting nut.

2. Adjusting nut lock nut.

3. Rod nut lock nut.

5. Posi clamp nut.

After raising saddle, remove saddle post clamp nut (5), which is located underneath frame at bottom end of post tube. Post assembly can then be pulled out. When post assembly is inserted in frame tube, see that flat side machined on post rod nut (4) registers in flat side of hole in bottom of tube. Cushion spring assembly (three lower springs) is adjusted 11 Vi" to 12" long. Adjustment can be changed for lighter or heavier than average rider and also different springs can be obtained if desired.

0 0

Post a comment