Differences

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--- techtalk:evo:body04 [2019/05/19 01:21]
ixl2relax [Brake Levers]
+++ techtalk:evo:body04 [2022/03/09 05:15]
ixl2relax ↷ Links adapted because of a move operation
@@ Line 84: / Line 84: @@
 |1998-2003 S Model Handlebars (56110-98) Flat Bar ((photo by Domino of the XLFORUM http://xlforum.net/forums/showthread.php?postid=5541539#post5541539))||
 ===== Aftermarket Bars =====
-See [[techtalk:ref:body12#aftermarket_handlebars_risers_and_mods|Aftermarket Handlebars, Risers and Mods]] in the REF section of the Sportsterpedia
+See [[techtalk:ref:body20#aftermarket_handlebars_risers_and_mods|Aftermarket Handlebars, Risers and Mods]] in the REF section of the Sportsterpedia
 ====== Clutch Levers ======
+clutch lever. \\
+{{:techtalk:evo:body:adjusting_-_removing_clutch_cable_11_by_hippysmack.jpg?direct&300|}} ((photo by Hippysmack)) \\
 Starting in 2007, the Clutch Lever had a switch implemented to allow it to be monitored. See the [[techtalk:evo:engctl03#clutch_switch|clutch switch function here]].
@@ Line 99: / Line 102: @@
 ====== Clutch Cables ======
+See also [[techtalk:evo:priclutch01#pics|Clutch Release Adjustment - Why & How]] including pics of adjusting the cable. \\
@@ Line 136: / Line 141: @@
 The second cable is named the Idle Cable and is connected to the carb throttle cam in the opposite direction from the throttle cable. The idle cable only serves as a backup function; it is not used to close the throttle unless the throttle cam return spring should break. However, the idle cable does provide some balance of tension against the throttle cable to prevent the throttle tube from rotating past the idle point.
-The throttle cam spring is quite strong & actually provides the tension on the throttle cable as you turn the throttle grip toward WOT. The idle cable is a safeguard in case this spring (on the carb) should break and the throttle plate remains open.
+The throttle cam spring is quite strong & actually provides the tension on the throttle cable as you turn the throttle grip toward Wide Open Throttle (WOT). The idle cable is a safeguard in case this spring (on the carb) should break and the throttle plate remains open.
-When installing the throttle/idle cable, the adjuster screws are turned all the way in to minimize the length of the sheath, in order to expose as much cable as possible, to make it easier to assemble the cable to the throttle tube & the carb throttle cam. Each cable has a ball end (used at the throttle tube) and a barrel end (that is used at the throttle cam).
+When installing the throttle/idle cable, the adjuster screws are turned all the way in to minimize the length of the sheath, in order to expose as much cable as possible, to make it easier to assemble the cable to the throttle tube & to the carb throttle cam. Each cable has a ball end (used at the throttle tube) and a barrel end (that is used at the throttle cam).
-The ball end of the cable is passed up through the lower switch housing. If you have the screw-in type cable, it would now be screwed into the lower switch housing. Then, the installable barrel is placed over the ball end and the barrel slid into the appropriate notch on the throttle tube. The slot in the installable barrel is inserted into the notch first. The throttle cable is located on the outward (front) side of the switch housing and the idle cable is located on the inward (rearward) side. Install both cables in like fashion.
+The ball end of the cable is passed up through the lower switch housing. If you have the screw-in type cable, it would now be screwed into the lower switch housing. Then, the installable barrel is placed over the ball end. This creates a barrel end out of the ball end. The barrel is now slid into the appropriate notch on the throttle tube with the side slot of the installable barrel to be inserted into the notch first. This will keep the cable from sliding out of the installable barrel.
+The throttle cable is located on the outward side (away from rider) of the switch housing and the idle cable is located on the inward side (nearest rider). Install both cables in like fashion.
@@ Line 148: / Line 155: @@
 Now route your cables past the forks and thru the fuel tank mounts down to the carburetor.
-The throttle cable is attached to the outward side of the throttle cam and the idle cable is attached to the inward (closest to the engine) side of the throttle cam. There are similar notches in the throttle cam as those located in the throttle tube and the crimped barrels on the cable ends fit into those notches.
+The throttle cable is attached to the outward side (closest to the air cleaner) of the throttle cam and the idle cable is attached to the inward side (closest to the engine) of the throttle cam. There are similar notches in the throttle cam as those located in the throttle tube and the crimped barrels on the cable ends fit into those notches.
-Route the idle cable up and into the side slot of the carb throttle bracket. Be sure to insert the spring (at the end of the idle cable) into the bracket cup so the idle cable sheath is buffered from the bottom of the cup.
+Once the ends are in the cam, route the idle cable up and into the side slot of the carb throttle bracket. Be sure to insert the spring (at the end of the idle cable) into the bracket cup so the idle cable sheath is buffered from the bottom of the cup.
 Route the throttle cable in a similar manner into the side slot of the bracket and make sure the cable sheath fits down into the bracket cup (there is no spring on the throttle cable end).
-Be sure both cable adjusters are fully minimized. Set the front wheel straight ahead. Turn the throttle grip to fully open (WOT) and hold it there. Turn the adjuster on the throttle cable so that the throttle cam is just touching the carb throttle stop. Release the throttle grip.
+\\
+===== Throttle Cables Bracket =====
+The Sportster CV40 carbs (from 1989-2006) used a Tall Cable Bracket.
+{{:techtalk:evo:body:throttlecablebracket-sportster.jpg?400|}}((Pic supplied by npaisnel of the XLForum)){{:common:space100x5px.jpg?30|}} {{:techtalk:evo:body:throttlecablebracket-bigtwin.jpg?400|}}((Pic supplied by npaisnel of the XLForum))
+Stock Sportster Cable Bracket:\\
+-2003 - 27316-88\\
+-2006 - 27320-04\\
+Sometimes carbs from other bikes would be swapped onto a Sportster and the new carb would have difficulty using the original cables. The swapped carb may have been from a Big Twin model that uses a shorter throttle cable carb bracket. Since the bracket is shorter, that requires that the outer sheath be longer (relative to the inner cable). Therefore, the length of the inner cable that is beyond the outer sheath of the throttle cables, often refered to as the free length, would be need to be shorter when using the Big Twin throttle cable bracket. Making the outer sheath longer also makes the free length of the inner cable shorter.
+(Note the bent arm on the Sportster bracket to reach the Carb Top, at the slide diaphragm cover. It also looks like the shorter BT bracket always has two holes drilled above the stop screw.)
+\\
+===== Adjusting The Throttle & Idle Cables =====
+The concept of adjustment here is to prevent the throttle cable from extra tension when the grip is fully in the WOT position. This is prevented by making sure the grip is at maximum rotation (WOT) before winding the adjuster to make the throttle plate reach the WOT Stop on the carburetor cam. It is important to adjust the cables in the following manner and sequence or your throttle cable may be overstessed every time you go to the WOT position, eventually breaking due to excessive tension.
+Be sure both cable adjusters are fully minimized. Set the front wheel straight ahead. Turn the throttle grip to fully open (WOT) and hold it there (using the throttle lock star wheel - or a helper). Turn the adjuster on the throttle cable, extending the outer sheath so that the throttle cam (pulled by the inner cable) is just touching the carb WOT Stop. Lock the adjuster in place and release the throttle lock at the grip.
+Turn the front wheel fully to the right. Now, turn the Idle Cable Adjuster so that the idle cable sheath just touches the spring in the carb throttle bracket cup. There should be some, but very little play at the throttle grip in the idle position.
+Check that the throttle snaps back to the idle position when you twist the throttle open and quickly release the grip.
+Start the engine and make sure it idles properly with the throttle grip fully clockwise (closed). Now open the throttle and quickly release it. It should spring back with a snap and resume a proper idle. Turn the front wheel fully left to fully right. The idle should not change.
+If, when moving the front wheel from left to right to left, the idle changes or the grip does not spring back into the idle position immediately upon release, readjust the idle cable adjuster to assure proper functioning and check that there is no tight bend or kink in the cable creating friction and preventing smooth operation.
+{{:techtalk:evo:body:throttlecableadjustment.jpg?800|}}
+The FSM has instructions for setting the CV40 throttle cables.\\
+But here's another explanation of how & why to adjust these cables:\\
+[[http://xlforum.net/forums/showthread.php?t=70825|Chris Hajer of the XLForum - See Post#2 & Post#9.]]
-Turn the front wheel fully to the right. Turn the adjuster on the idle cable so that the idle cable sheath just touches the spring in the carb throttle bracket cup.
-Start the engine and make sure it idles properly with the throttle grip fully clockwise (closed). Now open the throttle and quickly release it. It should spring back with a snap and resume a proper idle. Turn the front wheel fully left to fully right. The idle should not change. If the idle changes or the grip does not spring back into the idle position immediately upon release, readjust the idle cable adjuster to assure proper functioning and check that there is no tight bend or kink in the cable preventing smooth operation.
 \\
@@ Line 176: / Line 220: @@
 http://xlforum.net/forums/showthread.php?t=459983
+Cable 'Travel Distance' Too Long\\
+http://xlforum.net/forums/showthread.php?t=2073727
 Barnett - Custom Cables - Illustrations & Guide\\

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