11.116 ServiceManual-RocketIll

ThrottleCables

7. Detachtheinnercablesfromthethrottlecam.

8. Atthetwistgripend, removethescrewssecuringtherighthandswitchcubetothebrakemastercylinder.

2

?

Removal

Note:

• Priortoremoval,clearlyidentifytheopeningandclosingcablessothattheymayberefittedinthecorrectpositions.

1. Removetherider'sseat.

2. Disconnectthebatterynegative (black) leadfirst.

3. Raiseandpropthefueltankasdescribedonpage11.98.

4. Removetheintakecoverasdescribedonpage

11.98.

5. Removetheheadstockcover.

6. Slackentheadjusterlocknutsatthethrottlebodysuchthattheywillallowtheoutercablestobedetachedfromthecablebrackets.

1^"".^"Righihandswitchcube

2.Screws

9. Separatetheswitchcubefromthemastercylinder.

10.Releasethescrewandunionsecuringthethrottlecablestothemastercylinder.

1. Throlllecables

2. Screw

3. Union

1^-.Openingcable adjuster

2. Closingcableadjuster

3. Locknuls

ServiceManual-RocketIll

11.117

11.Release,butdonotremovecompletely,thetwoscrewssecuringthemastercylindertothehandlebar.

1. Mastercylinder

2. Screws

12.Easethemastercylinderawayfromthehandlebartoallowspaceforthethrottlecablestobedetachedfromthetwistgrip.Detachthecablesfromthetwistgrip.

1. Twistgrip

2. Throttlecables

13.Notetheroutingofthethrottlecables,thenremovethemfromtheframe.

Examination

1. Checkthatthethrottlecablesoperatesmoothly,withoutstickingorbinding.Replacethecableifthereisanydoubtastoitscorrectoperation.

InstallationNote:

• Theopeningandclosingcablesmustbecorrectlyidentifiedandfitted tothecorrectpositionsasnotedpriortoremoval.

1. Locate thecablestotheframefollowingtheroutingnotedduringremoval.

2. Engagethenipplesoftheinnercablestothetwistgrip.

3. Locatethemastercylindertothehandlebars.

4. Positiontheclamptotherearsideofthehandlebars.

5. Alignthemastercylinder/clampsplitlinewith thedotmarkontheundersideofthehandlebar.

0

cbsz

1. Splitline

2. Dotmark

6. Tightenthemastercylinderclampbolts,upperfirstandthenthelowerto15Nm.

7. Assembletheswitchcubetothemastercylinder,tighteningthetwoscrewsto4Nm.

8. Attachthecableretainerscrewanduniontothemastercylinder,tighteningbothto3Nm.

1. Throttlecables

2. Retainerscrew

3. Union

^11.118 ServiceManual-Rocket Ill

9.Attachtheotherendoftheinnercablestothethrottlecamandlocatetheoutercablestothecablebracket. Ensuretheopeningandclosingcablesarelocatedtothecorrectcamsthenfitthecablelocknuts.

1^-.Openingcableadjuster

2. Closingcableadjuster

3. Locknuts

Throttlecableadjustment

1.Whencorrectlyset,thethrottlemusthave2-3mmoffree-playatthethrottletwistgrip.Ifthereismore orlessthan2-3mmoffree-playpresent,thethrottle cablesmustbeadjusted.

1.Throttletwistgrip2.2-3mm

Ifthereisanincorrectamountoffree-play,adjustmentmaybemadeasfollows:

10. Refittheheadstockcover.

11. Supportthetank,removeandstowthetankprop,thenlowerthetanktotheframeandsecureitasdescribedonpage11.99.

12. Refittheintakecover(seepage11.99).

13. Reconnectthebattery,positive(red)leadfirst.

14. Refittherider's seatasdescribedonpage17.9.

15. Setthecableadjustmentusingtheadjustmentinstructionsthatfollow:

ServiceManual-RocketIll

11.119

5

1. Openingcableadjuster

2. Closingcableadjuster

3. Locknuts

4. Closingcable-freeplaymeasurementpoint

5. Openingcable-freeplaymeasurement point

2. Removetheintakeandheadstockcoversifnotalreadyremoved.

3. Releasethelocknutonthe'opening'cableadjuster.

4. Rotatethe'opening'cableadjusteratthetwistgripendsuchthatithasanequalamount ofadjustmentineachdirection.

5. Rotatethe'opening'cableadjusteratthethrottlebodyendofthecabletogive2-3mmofplayatthetwistgrip.Tightenthelocknut.

6. Makeanyminoradjustmentsasnecessarytogive2-3mmofplayusingtheadjusternear thetwistgripendofthecable.Tightenthelocknut.

7. Withthethrottlefullyclosed,ensurethatthereis2-3mmoffreeplayinthe'closing'cableatthethrottlecamattachedtothethrottlebodies.Ifnecessary,adjustinthesamewayasthe'opening'cableuntil2-3mmofplayispresent.

2. Refittheintakecover,tighteningthescrewsto

9Nm.

2. Checkthatthethrottleopenssmoothly,withoutundueforceandthatitcloseswithoutsticking.Rectifyasnecessary.