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1.
Loosen throttle and return cable locking nuts.
a. Pay
attention to original position so you can return at re-assembly.
b. Loosen cable adjustments to provide slack in cables for removing from
grip. |
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2.
Remove two socket cap screws that hold housing halves together.
a.
Screws should use a 3/16 Allen wrench and are accessed from front
of bike. |
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4.
Separate switch housing and very carefully unplug wiring from
rear half of housing.
a.
Printed circuit board and plug are very delicate so when
unplugging wiring connector be sure to pull straight to avoid bending
any of the connector pins. |
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5.
Remove cables from grip and switch housing, being careful not to
lose small brass ferrules at the end of cables.
a.
Applying a small amount of oil (we use WD-40) around the cable
ends inside the housing will help the cable snap rings release from
housing.
b.
Wiggle cable end back and forth while pulling down to remove
cables from housing.
c.
If your cable ends are threaded into housing (this is not the
case in most situations) simply unscrew from housing. |
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6.
Remove original equipment thumbscrew from bottom of housing (if
applicable) |
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7.
Reassemble switch housing halves off of handlebar |
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8.
Turn housing upside down and install drill jig into cable holes
in bottom of housing.
a.
Jig will only fit one way. |
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9.
Place clamp bar (flat bar with two holes drilled in it) inside
switch housing, thread drill jig bolts into bar and tighten hand tight. |
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10.
Insert alignment pin in drill jig bushing and push so tip of pin
goes into original threaded hole in bottom of housing. |
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11.
Tighten drill jig bolts wrench tight ensuring alignment pin keeps
jig aligned with original threaded hole. |
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12.
Remove alignment pin from drill jig. |
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13.
Carefully drill new hole using 21/64 drill bit (fig 3). |
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14.
Remove bushing from jig and using the hole in jig to guide tap,
thread newly drilled hole with 3/8-24 tap.
a.
The majority of the 3/8-24 thread will be in the front half of
the housing, however, a very small amount of the thread will overlap
into rear half of housing, THIS IS NOT A PROBLEM.
b. If using a starting tap (tapered) the tap will hit the tie bar that
holds the drill jig before the hole is completely threaded, simply
remove the jig from the control and finish tapping without the jig in
place or finish threads with a bottoming tap. |
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15.
Remove drill jig from housing. |
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16.
Apply a small amount of Loctite to 3/8-24 threads of Cruise-Mate
cartridge, thread into newly tapped hole and tighten. |
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17.
Thread Cruise-Mate stud out of bushing far enough so that stud is
not pushing on spring. |
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18.
Separate housing and be very sure to remove all chips created by
drilling and tapping.
a.
Any debris left in housing could eventually work its way into
cables or printed circuit board and cause catastrophic results. |
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19.
Reassemble switch housing and master cylinder on handlebar,
adjust to correct position and tighten bolts. |
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20.
Thread Cruise-Mate stud into bushing until you feel light contact
with grip. |
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21.
Remove shoulder bolt and spring from end of Cruise-Mate stud. |
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22.
Apply a very small amount of Loctite to shoulder bolt threads and
place handle on stud and reinstall spring and shoulder bolt. |
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23.
Refer to operating
instructions to set Cruise-Mate to operating condition. |
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IF YOU EXPERIENCE ANY PROBLEMS OR HAVE
ANY QUESTIONS REGARDING INSTALLATION OF CRUISE-MATE
PLEASE CALL 877.642.3722. |
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