Install Brake And Travel Clutch Cables

  1. TCT008669
    TCT008669-UN-11SEP13

    Route cables (A) through slotted hole in lower handlebar bracket (B).


  2. NOTE: Slide caps (C) off threaded ends of cable ferrules. Rotate jam nuts (D) as needed to fit cables into slots in handlebar bracket (F). Verify one jam nut is on either side of bracket before tightening. Slide caps onto threaded end of cable ferrules after jam nuts are tightened.

    TCT008670
    TCT008670-UN-11SEP13

    Put brake cable (E) into upper slot in handlebar bracket (F), and place clutch cable (G) into lower slot.


  3. TCT008671
    TCT008671-UN-11SEP13

    Remove carriage bolt and nut (H).


  4. Rotate brake lever (I). Insert end of cable (J) into hole in brake lever arm.

  5. NOTE: Cable end must swivel freely.

    Reinstall carriage bolt and nut. Tighten nut.

  6. Apply a small amount of grease to the cable end.

  7. TCT008672
    TCT008672-UN-11SEP13

    Fasten end of travel clutch cable to hole in travel clutch bracket with drilled pin (K) and cotter pin (L).


  8. NOTE: Do not over tighten nuts. Excess torque may damage threads on ferrule body.

    If necessary, adjust cables. Tighten nuts to 11 N·m (96 lb.-in.).

  9. Install tie straps.

  10. Adjust cables. (See “Drive Belt Tension Check and Adjustment” and “Adjusting Brake” in this section.)

OUMX068,00001BD-19-20130912