Screw R, -4, Hex locknut S. Tighten securely

Section 2: Assembly

STEP 4: Install Forward Clutch Cable

1. Place the forward clutch cable bracket (P, Fig.

2-4) on the handlebar support (A). Attach the

cable bracket using a 1/4"-20 x 1-1/4" hex hd.

screw (R, Fig. 2-4) and

1/4"-20 hex locknut (S). Tighten securely.

2. Carefully unwrap the forward clutch cable

(the cable without a knob attached to it) 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 on the bracket.

3. Insert the #10-24 x 2" slotted hd. screw (V,

Fig. 2-5) down into the cable spring (W). The

screw threads will extend down through the

spring.

4. Thread the #10-24 hex nut (Z, Fig. 2-5) on

the screw (V). Thread the hex nut about halfway

up the screw.

	R
P	T
P	A
	T
	U
S

Fig. 2-4: Installing forward clutch cable bracket and cable.

5.	Thread the screw (V) 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. Check for 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 and

carefully note the overall length of the

cable spring (W) by measuring 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 overall length of the coils

Fig. 2-5: Assemble spring and adjuster.

Fig. 2-6: Install forward clutch cable.

while the spring is under tension. The belt

tension is correct if this second measure-

ment is between 1/16" -to- 3/16" longer

than the first measurement. If so, turn the

hex nut (Z, Fig. 2-7) tightly against the

cable adjuster (X) while preventing the

adjuster from turning.

c. If the spring length is incorrect, you must

make an adjustment to 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 unintentional tine movement

when the clutch bail is in Neutral (tension

too tight).

X	Z	1
X

Hold bail against handlebar while taking second measurement of spring

Fig. 2-7: To check forward belt tension, take two measurements of the overall length of the coils in the spring – first with the clutch bail open, then with the clutch bail closed against the handlebar.