Servicing Handlebar Controls

(To Identify Items, Refer to Iilus. 19)

To lubricate control parts, or to replace a throttle or spark control wire, or a damaged control wire housing, proceed as follows:

Disconnect control wire at carburetor or circuit breaker. Insert a large heavy screw driver through hole in end of grip as shown in Illus. 18 and turn out end screw (A) by using a wrench on screwdriver. Sometimes this screw is difficult to remove. In this case, insert a punch in slot in screw and strike it two or three sharp blows to start it. After removing grip sleeve assembly (C), working parts are accessible. Remove roller (E), roller block (F), and roller pin (D). Plunger (G), with control wire (H) attached, can now be pulled out of handlebar end. If wire is broken, remove other half from housing at connection end. Wire is fastened into end of plunger by means of a hexagon head screw (I) with a hole through it.

Remove any rust, dirt or gum from grip spiral, handlebar end, wire plunger, and inside of handlebar where plunger operates.

If control wire housing is to be removed, first remove grip control parts as explained above. Then, remove the small lock screw underneath handlebar, just ahead of spiral locating shoulder on bar (on left bar, this screw is under headlamp dimmer switch). After lock screw is removed and housing freed from housing clamp or clamps, it can be pushed out through end of handlebar.

When installing control wire housing, see that housing end is secured in handlebar with lock screw (screw must register in groove in control coil plug) and that housing is secured with clamp or clamps.

When reassembling control parts to handlebars, apply a light coat of grease or a few drops of engine oil to control wire as it is inserted into control housing, and lubricate remaining parts with grease (see "Lubrication Chart," Page 9). Overgreasing of these parts will cause a messy condition.

End screw (A) can best be started, without danger of crossing threads, by holding grip sleeve assembly

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