Service Bulletin 2-17 Installation Of Clutch Cables Model 149-249

INSTALLATION OF CLUTCH CABLES
Model 149-249

To improve the operation of the clutch control and to prevent chafing and wear between the cable and casing, the control should be located as shown.

ADDITIONAL PARTS REQUIRED:

Standard Handlebar
1 – 1314005 – Clip – cable to upper front tank bold
Western Handlebar
1 – 25B157 – Clip
1 – 754403 – Screw
1 – 922004 – Lockwasher

INSTALLA’TION OF CLUTCH CABLE WITH STANDARD HANDLEBARS

INSTRUCTIONS:

1. Lead the clutch cable up between the steering damper wheel and the left handlebar mounting bracket, as shown in Sketch #1 and #2, and attach to the handlebar bracket.
2. Assemble clip #1314005 to front upper tank bolt to hold cable in position so that there is a full curve between the handlebar bracket and the tank clip, making sure the casing leaves the bracket in a straight line, as shown in Sketch #3.

SKETCH #1
Cable and clip location at tank bolts.
SKETCH #2
Cable location at handlebars.
SKETCH #3
Cable location a. t hand lever.

Page 2, see drawing above.

INSTALLATION OF CLUTCH CABLE WITH WESTERN HANDLEBARS

INSTRUCTIONS:

1. Lead the clutch cable up between the frame head fitting and left fork leg and attach to hand lever bracket.
2. Install clip to speedometer bracket —
   A. Open up the hold in the left side of the speedometer bracket with a #21 drill and thread with a #10-32 tap.
   B. Place the clip, #28B157, over the clutch cable casing with the screw hole to the rear.
   C. Raise the casing so that there is a full curve between the handlebar and the speedometer mounting clip, making sure the casing leaves the bracket in a straight line.
   D. Adjust the clip on the casing. Align the clip hole with the bracket hole and and install screw and lockwasher.

SKETCH #1
Cable location at band lever.
SKETCH #2
Cab.le location at speedometer bracket .
SKETCH #3
Cable and clip location at lower tank bolt.

GENERAL INSTRUCTIONS ON ALL HANDLEBARS:

Some owners may bend their handlebars or install with the brackets reversed, which will make it necessary to work out a different installation. Watch the following points:

1. Be sure that the outer casing is fixed so that the inner cable is pulling in a straight line when the hand control lever is at the half way position.
2. Make all bends as large as possible and use clamps to keep the bends from shifting.
3. If the casing is cut shorter, be sure the inside is cleaned up to remove burrs and to have a slight internal taper.
4. Keep the cable greased.
5. Be sure the casing will not chafe or be pinched as the front fork is turned for steering.

Page 4, see drawing above.