2008 KTM 65 SX 65 XC OWNER'S MANUAL

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Filed Under (KTM) by admin on 09-03-2012

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SERIAL NUMBER LOCATIONS » OPERATION INSTRUMENTS » Chassis number The chassis number is stamped on the right side of the steering head tube. Enter this number in the field on page no 1. Engine number The engine number is stamped into the engine housing underneath the carburetor. Enter this number in the field on page no 1. Clutch lever The clutch lever [1] is located on the left side of the handlebar. The adjusting screw [A] is used to change the original position of the clutch lever (see maintenance work on chassis and engine). The clutch is hydraulically actuated and adjusts itself automatically. Hand brake lever The hand brake lever [2] is mounted on the handle bars on the right and actuates the front wheel brake. The adjusting screw [B] can be used to change the basic position of the hand brake lever (see maintenance work on chassis and engine). 1 A 2 B
ENGLISH 7 OPERATION INSTRUMENTS » Short circuit button The short circuit button [1] turns off the engine. When pressing this button, the ignition circuit is short-circuited. Filler cap To open it: turn filler cap counter-clockwise. To close it: put filler cap back on and tighten it by turning it clockwise. Install tank breather hose [2] without kinks. Fuel tap The fuel tap [3] is located on the left side of the tank. Opening the fuel tap: Turn the knob all the way to the left. Closing the fuel tap: Turn the knob all the way to the right. Choke The choke button [4] is located on the left side of the carburetor. Pulling the choke button all the way out opens a bore in the carburetor through which the engine can take in additional fuel, thus achieving the „rich” fuel air mixture needed for cold starting. Pushing the choke button back in closes the bore in the carburetor. Shift lever The shift lever is mounted on the left side of the engine. The position of the gears is shown in the illustration. Neutral, or the idle speed, is located between first and second gear

KTM 2010 450 EXCUSA 530 EXCUSA INSTALLATION MANUAL

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Filed Under (KTM) by admin on 03-02-2012

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Clutch lever 500133-10 The clutch lever  is fitted on the left side of the handlebar. The clutch is hydraulically operated and self-adjusting. Hand brake lever 400196-10 Hand brake lever  is located on the right side of the handlebar. The hand brake lever is used to activate the front brake. EmergencyOFFswitch 500144-10 The emergency OFF switch  is fitted on the left side of the handlebar. Possible states Ignition off-In this position, the ignition circuit is interrupted, a run- ningenginestops, and anon-running engine will not start. Ignition on-In this position, the ignition circuit is closed, and the engine can be started. Ignition switch 300396-10 The ignition switch  is on the right behind the headlight mask. Possible states Ignition off-In this position, the ignition circuit is interrupted, a run- ningenginestops, and anon-running engine will not start. Ignition on-In this position, the ignition circuit is closed, and the engine can be started. Electrics tarter button 500144-12 Electric starter button  is fitted on the right side of the handlebar. Possible states •Electric starter button is in home position •Electric starter button is pressed-In this position, the electric starter is actu

HONDA CR250R Owner’s Manual

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Filed Under (Honda) by admin on 24-04-2011

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l. CONTROLS( 1 ) Frontbralte tever (2) Throttle grip ( 3 ) Engine stop switch When shutting off engine, press in the  engine stop switch button. (4 ) Rear brake pedal ( 5 I Kickstarter pedal ( 6 } Clutch lever (1′) Fuel tank filler cap ( 8) Gear change pedal The transmission has S speeds. Depress the pedal to Shift into [st gear. Raise the pedal to shift into 2nd, 3rd, 4th and 5th. Neutral is located between 1st and 2nd.  9 ) Fuel mixture enrichment l-mob When starting a cold engne, raise the fuel mixture knob and fully depress the kickstarter pedal. (10) Fuel valve When the fuel valve is turned to "OFF", fuel cannot Flow from the fuel tank to the carburetor. When the fuel valve is turned to “ON”, fuel will flow from the tank to the carburetor. (1 1] Rear shock absorber adjuster The rear shock absorber springs have three settings for precise adjustment of the rear suspension to suit riding conditions and differences in rider weight. Page 6 2 l. OPERATING – Fig. l—2 (1) Fuel tank -  2. FUEL The Honda CRZSUR ELSINORE has a two-stroke engine that requires a gasoline-oil mixture. The capacity of the “fuel tank is 8.59 (2.2 US gal. 1.9 Imp. gal). I Any automotive gasoline with :1 pump octane number of 86 or higher. or research octane number of9i or higher‘ may he used. If “l ofgasoline or a higher octane grade. USE HONDA 2-STROKE INJECTOR OIL OR EQUIVALENT. I Premix gasoline and oil in a ratio of   20:1 Prepare the fuel mixture in a clean container, and shake until thoroughly mixed before Flling the fuel tank. i Too much oil will muse excessive smoking and spark plug fouling. Too little oil will cause engine damage or premature wear. Mix fuel in a ratio of 20 parts gasoline to 1 part oil. I Vegetable oils separate from gasoline more easily than mineral oils, especially in cold weather. It is advisable to use mineral oil when ambient temperatures of below 0°C (32°F) are expected. I If the gasoline-oil mixture is left standing in a container for a long period of time, lubricity will deteriorate. Use the mixture within 24 hours. I Once an oil container is opened, the oil must be used within one month, since oxidation may occur. Do not mix vegetable and mineral oils. Gasoline is flammable and explosive under certain conditions. Always stop the engine and do not smoke or allow open flames or sparks near the motorcycle when refueling

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HARLEY DAVIDSON SPORTSTER CHROME PRIMARY TRIM COVER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 08-03-2011

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INSTALLATION To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Owner’s Manual and follow the instructions given to remove the seat and disconnect the negative battery cable at the engine crankcase. Retain all seat mounting hardware. 2. Models with mid foot controls: Remove the two screws retaining the left-side rider footrest and mounting bracket assembly. 3. All models: See Figure 1. Note the installed orientation of the transmission foot shift lever to aid in re-assembly. Use a 1/4 in. hex key to remove the socket head screw (5) holding the shift lever (3 or 4) to the transmission shift lever shaft (1). Remove the lever and rubber washer (2). 4 1 5 3 2 5 is 01929 1. Transmission shift lever shaft 2. Rubber washer 3. Foot shift lever (mid control) 4. Shift lever (forward control) 5. Socket head screw Figure 1. Shift Lever Removal 4 2 3 1 is 01930 Figure 2. Primary Cover Mounting Screw Locations NOTE Remove ONLY the four screws shown. 4. See Figure 2 and Figure 3. Remove and discard the primary cover hex-socket head screws from the four locations shown. 5. Refer to CLUTCH CONTROL: REMOVAL: CLUTCH CABLE-LOWER in the Service Manual to remove the clutch cable at the lower end with these exceptions: •The negative battery cable has already been disconnected, and •On mid-control models, the rider footrest has already been removed. 6. See CLUTCH LEVER AND CLUTCH CABLE-UPPER to remove the clutch cable at the upper end. NOTE Be careful not to scratch the paint on the frame tube when removing the clips. 7. Carefully remove the two vinyl-coated spring steel clips that retain the clutch cable to the frame downtube. 8. Obtain all of the items from the kit. 9. See Figure 2. Insert a chrome screw (3), from the outside, through the hole in location 3 on the chrome trim cover. Place the thinner steel spacer (4) onto the threads of the screw from the inside of the trim cover. 10. Use a 5/32 inch hex key on the screw head, and grip one of the Nylon keeper washers (6) with a pliers. Install the washer onto the screw until several threads extend from the washer, capturing the screw and spacer on the trim cover. 11. Insert the remaining chrome screws, from the outside, through the holes in locations 1, 2 and 4 on the chrome trim cover. Place a thicker steel spacer (5) onto the threads of each screw from the inside of the trim cover. 12. Thread a Nylon keeper washer onto each of the screws as described in Step 10. 13. Position the trim cover over the primary cover with the transmission shift lever shaft extending through the clearance hole (A) in the chrome trim cover. 14. Thread one of the chrome screws into the mating primary cover mounting hole for several threads, taking care not to cross-thread the screw in the hole. 15. Carefully start the remaining screws partially into their mating holes. Continue tightening the screws in turn

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HARLEY DAVIDSON AILERON HAND GRIPS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 01-03-2011

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LEFT GRIP REMOVAL AND INSTALLATION 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp, and position the clutch hand lever assembly away from the handlebar. 2. Using a T25 TORX drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left hand grip if so equipped. With “glueless” grip: Remove the grip from the han- dlebar. With glued grip: Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. NOTE Make sure that the handlebar surface and the inside of the new grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) 4. Position the new left grip (4) so the larger diameter portion of the flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8- 9.0 Nm). 9. Using a T25 TORX drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4.0-5.1 Nm)

HARLEY DAVIDSON SPORTSTER HAND GRIPS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 24-02-2011

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Remove and Install the Left Grip 1. See Figure 1. Using a T27 TORX®drive head, remove the two screws with flat washers securing the handlebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar. 2. Using a T25 TORX®drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX®drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9.0 Nm). 9. Using a T25 TORX®drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4.0-5.1 Nm). Remove and Install the Right Grip 1. Refer to the RIGHTHANDLEBARSWITCH section of the service manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLECONTROL section of the service manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the service manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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HARLEY DAVIDSON HANDLEBAR RESERVOIR COVER SET INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 13-02-2011

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Kit 46098-98 fits the following models with single-disc front brake. •1996 through 2003 XL (Sportster®) models •1996 and later Dyna models •1996 and later Softail® models Kit 46099-98 fits the following models with dual-disc front brake. •1996 through 2003 XL (Sportster) models •1996 and later Dyna models •1996 and later Softail models •1996 and later FL Touring models INSTALLATION Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Make sure you are using the correct retaining-ring pliers. Verify that tips of pliers are not excessively worn or damaged. 1. Adjust the clutch cable for maximum free play. With snap ring pliers, remove and retain the external snap ring from the bottom of the clutch lever pivot pin. Remove the pivot pin, clutch lever, clutch cable and rear-view mirror from the clutch bracket. NOTE Apply anti-seize (10) (Harley-Davidson part number 98960-97) from the kit to all screw threads prior to installation. 2. See Figure 1. Install the new chrome clutch bracket (1) using a clamp half (2), washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). -J01271 1 is01004 Figure 2. Clutch Cable Adjustment 3. Re-install the clutch cable and clutch lever, mirror and pivot pin and snap ring. See Figure 2. Re-adjust the clutch cable so there is a 1/16-1/8 inch (1.6-3.1 mm) gap between the clutch cable ferrule and the end of the clutch bracket (1). 4. Remove the original clamp half from the front brake master cylinder assembly. 5. See Figure 1. Install the new chrome clamp half (2) on the front brake master cylinder assembly using washers (3) and screws (4) from the kit. Tighten the screws to 70-80 in-lbs (7.9-9.0 Nm). 6. Remove the two screws retaining the brake master cylinder reservoir cover. See Figure 3. Replace with the two standoff studs (1) in the kit. Tighten to 6-8 in-lbs (0.7-0.9 Nm)

HARLEY DAVIDSON FLAME HANDLEBAR GRIPS REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 12-02-2011

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REMOVE AND INSTALL THE LEFT GRIP 1. See Figure 1. Using a T27 TORX® drive head, remove the two screws with flat washers securing the handebar clamp (3) to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar 2. Using a T25 TORX® drive head, loosen but do not remove the upper and lower switch housing screws (1). 3. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (00315a) NOTE Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 4. Position the new left grip (4) so the larger flange (5) is at the bottom. Push the grip fully onto the handlebar. 5. Fit the grooves (2) on the outboard side of the upper and lower switch housing over the flanges on the end of the grip, then loosely fasten the two screws. 6. Position the clutch hand lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. 7. Align the holes in the handlebar clamp with those in the clutch lever bracket, and loosely fasten the two screws with flat washers. Adjust the switch housing and clutch hand control position for rider comfort. 8. Using a T27 TORX® drive head, tighten first the upper, then the lower handlebar clamp screws to 60-80 in-lbs (6.8-9 Nm) . 9. Using a T25 TORX® drive head, tighten first the lower, then the upper switch housing screws to 35-45 in-lbs (4- 5.4 Nm) . 5 3 1 1 4 2 2 is00735 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger flange Figure 1. Left Handlebar Switch Housing REMOVE AND INSTALL THE RIGHT GRIP NOTE Right handlebar switch removal requires a Service Manual for your model and year of motorcycle. A Service Manual can be purchased from your Harley-Davidson Dealer. 1. Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual for removal of the switch housing assembly. This is necessary to access the throttle cables. 2. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables and remove the existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 3. Follow instructions in the Service Manual to install the new right grip/throttle sleeve to the handlebar and connect the throttle cables. 4. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.

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HARLEY DAVIDSON DIAMONDBACK "LE" CHROME SERIES CLUTCH CABLE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-02-2011

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CLUTCH CABLE REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. Disconnect the battery or main fuse following the instructions in the appropriate Service manual. 2. When performing cable disassembly procedures, make careful notes as to the existing cable routing and existing cable strap locations. New straps can be installed in the same locations. 3. Remove the clutch cable following the instructions in the appropriate Service Manual. 4. If installing different handlebars, install them now (refer to the appropriate handlebar instruction sheet) and measure the change in distance that will be required from the end of the cable housing to the clutch lever. Install proper length clutch cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00448b) 5. Compare the additional required length to the cable provided in your kit. If the cable is more than two inches (50.8 mm) longer or more than one inch (25.4 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length. CLUTCH CABLE INSTALLATION Sportster and Softail Models Do not over-tighten clutch cable threaded end fitting. Use recommended torque values. Damage to threaded fitting can lead to loss of transmission fluid, which could result in loss of control and death or serious injury. (00449c) -J04568
NOTE Damage to the clutch cable threaded end fitting due to improper handling/installation is not covered under the Harley-Davidson Motor Company Warranty. 1. See Figure 11. Apply a light coat of clean engine oil on the new O-ring (2) before installing the O-ring onto the threaded portion of the clutch cable end. 2. Install the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). 3. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet. FLTR Models with Fairing Lowers 1. See Figure 1. Carefully twist the clutch cable around the coiled opening in the clutch cable guide (2) with the eyelet toward the left handlebar. 2. Route the clutch cable assembly down from the clutch cable clamp while crossing to the right side of the vehicle. Run the cable between the inboard side of the right frame downtube and the outboard side of the voltage regulator. 3. The clutch cable clamp, mounted on the engine guard, has two fingers, an upper and a lower. Feed the cable assembly under one finger and over the other. 4. Finish the installation of the clutch cable following the instructions in the appropriate Service Manual EXCEPT: Tighten clutch cable fitting to clutch release cover to 36-60 in-lbs (4-7 Nm) . Replace anchor pin with anchor pin supplied in this kit, see Figure 11, item (1 or 7). NOTE See Figure 2. Adjust the clutch cable clamp to 2.25 ± 0.25 in. (57.15 ± 6.35 mm) as measured from the inside lower left fairing mount to the clutch cable clamp. 5. After installation, follow the instructions in the “Final Assembly” and “Clutch Cable Adjustment” sections in this instruction sheet.

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HARLEY DAVIDSON HEATED HAND GRIP KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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REMOVAL Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Remove the fuel tank according to the service manual instructions. -J04259 1 of 8 Left-Side Grip Removal 1. See Figure 1. Using a T-25 TORX drive head, remove the upper and lower switch housing screws (1). 2. Using a T-27 TORX drive head, loosen the upper screw securing the handlebar clamp (3) to the clutch lever bracket. Remove the lower clamp screw with flat washer. Loosen the clamp and position the clutch hand lever assembly away from the switch housing. Separate the upper and lower switch housings. 3. With “glueless” grip: Remove the grip from the handlebar. With glued grip: Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. 2 2 1 5 4 3 1 is01283 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger diameter of flange Figure 1. Left Handlebar Switch Housing Right-Side Grip Removal Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 2. 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. 2. Using a T-25 TORX® drive head, remove the upper and lower switch housing screws. 3. Using a T-27 TORX drive head, loosen the upper screw securing the handlebar clamp to the brake master cylinder housing. Remove the lower clamp screw with flat washer. Loosen the clamp and position the master cylinder assembly away from the switch housing. Separate the upper and lower switch housings. 4. Remove the grip from the handlebar. NOTES The twist grip sensor in the right side of the handlebar has a seal cap that protects internal electrodes from dirt and moisture, and also serves as a retention device for the throttle grip. To remove the grip, a slight tug may be necessary to release the index pins in the grip from the receptacle in the seal cap. Upon removing the grip, check the location of the seal cap. If the seal cap is still fastened to the index pins inside the old throttle grip, it can be discarded along with the grip. If the seal cap is still fastened to the end of the twist grip sensor: •See Figure 3. Insert a small screwdriver or other flat-blade tool into the flat area on one side of the seal cap. •Press the leg on the underside of the cap to free it from the slot at the end of the twist grip sensor. Pry up one end of the cap. •Repeat on the other side of the cap. •Carefully remove the cap and discard it

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