routed incorrectly or there is insufficient cable free
play. Make the necessary corrections.
CONTROL CABLES
Lubricate and adjust the control cables at the in-
tervals specified in
Table 1
. When lubricating a ca-
ble, also inspect it for fraying and check the cable
sheath for chafing.
Cables can be lubricated with a cable lubricant
and a cable lubricator as shown in
Figure 40
. Do
not use chain lube to lubricate the cables.
If necessary, refer to
Throttle Cable Adjustment
in this chapter.
NOTE
The main cause of cable breaking or
cable stiffness is improper lubrica
tion. Maintaining the throttle cable as
described in this section ensures a
long service life.
Throttle Cable Lubrication
1. Remove the two mounting screws and separate
the halves of the right handlebar switch assembly as
described in Chapter Nine.
2. Disengage the ends (A,
Figure 41
) of both the
pull and push cables from the throttle drum.
3. Attach a cable lubricator to the cable following
the manufacturer’s instructions.
4. Insert the nozzle of the lubricant can into the lu-
bricator (
Figure 40
), press the button on the can and
hold it down until the lubricant begins to flow out of
the other end of the cable.
NOTE
Place a shop cloth at the carburetor
end of the cable to catch all excess lu
bricant that flows out.
NOTE
If lubricant does not flow out the end
of the cable, check the entire cable for
fraying, bending or other damage.
5. Remove the lubricator, reconnect the cables and
adjust the throttle cable as described in this chapter.
When installing the right handlebar assembly, make
sure the pin (B,
Figure 41
) on the switch assembly
aligns with the hole in the handlebar.
Clutch Cable Lubrication
1. At the handlebar, slide the clutch lever boot (A,
Figure 42
) away from the adjuster.
2. Loosen the clutch cable locknut (B,
Figure 42
)
and rotate the adjuster (C) to provide maximum
slack in the cable.
3. Disconnect the cable end from the clutch hand
lever.
LUBRICATION, MAINTENANCE AND TUNE-UP
71
3
39
40
41