Harley Davidson Softail 2000-2005. Service manual — page 21

gear where applicable. Make sure the gears are correctly
assembled before installing the shaft assemblies into the
transmission case.

MAIN DRIVE GEAR

The main drive gear (Figure 97) and bearing assembly

are pressed into the transmission case. If the transmission
case is installed in the frame, a special transmission main
drive gear tool set (JIMS part No. 35316-80) (Figure 98)
is required to remove the main drive gear. If the transmis-
sion has been removed, use a press to remove and install
the main drive gear.

Whenever the main drive gear is removed, the main

drive gear bearing must be replaced at the same time.

Removal

1. Remove the transmission shaft assemblies from the
transmission case as described in this chapter.

2. Remove the spacer from the main drive gear oil seal.

3. Remove the circlip behind the bearing.

NOTE

If the main drive gear will not loosen from
the bearing in Step 4 due to corrosion, re-
move the special tools and heat the bearing
with a heat gun.

4. Assemble the special tool set onto the main drive gear
following the manufacturer’s instructions. Then tighten
the puller nut slowly to pull the main drive gear from the
bearing in the transmission case.

5. Remove the main drive gear bearing from the trans-
mission case as described in this section.

Inspection

1. Clean the main drive gear in solvent and dry it with
compressed air, if available.

2. Check each gear tooth (A, Figure 99) for excessive
wear, burrs, galling and pitting. Check for missing teeth.

3. Check the gear splines (B, Figure 99) for excessive
wear, galling or other damage.

4. Inspect the two main drive gear needle bearings for ex-
cessive wear or damage. Refer to Figure 100 and Figure
101. Insert the mainshaft into the main drive gear to check
bearing wear. If necessary, replace the bearings as de-
scribed in this section.

254

CHAPTER SIX

97

MAIN DRIVE GEAR

1. Bearing
2. Main drive gear
3. Transmission case
4. Bearing
5. Mainshaft bearing—left side
6. Snap ring
7. Quad seal
8. Oil seal
9. Sprocket spacer

98

96

Bearing Replacement

Main drive gear needle bearings

Both main drive gear needle bearings must be installed

to a correct depth within the main drive gear. The correct
depth is obtained with a main drive gear bearing tool
(JIMS part No. 37842-91). This tool also installs the oil
seal. If this tool is not available, a press is required.

If the special tool is not available, measure the depth of

both bearings before removing them.

Replace both main drive gear needle bearings as a set.

CAUTION

Never reinstall a main drive gear needle
bearing, as it is distorted during removal.

1. Remove the oil seal (Figure 102) from the clutch side
of the main drive gear.

2. If the special tool is not used, measure and record the
depth of both bearings.

3. Support the main drive gear in a press and press out
one needle bearing. Then turn the gear over and press out
the opposite bearing.

4. Clean the gear and its bearing bore in solvent and dry
them thoroughly.

5. Apply transmission oil to the bearing bore in the main
drive gear and to the outer surface of both bearings.

NOTE

Install both needle bearings with their man-
ufacturer’s name and size code facing out.

6A. Install the bearings with the special tool as follows:

a. The special tool has two different length ends. The

tool’s long side (A, Figure 103) is for the clutch
side of the main drive gear (Figure 101). The tool’s
short side (B, Figure 103) is for the transmission
side of the main drive gear (Figure 100).

TRANSMISSION

255

6

100

101

102

103

99

b. Install the main drive gear in a press with the trans-

mission end facing up. Align the new bearing with
the main drive gear and insert the installation tool
with the

short side facing down

(Figure 104) into

the bearing. Operate the press until the tool’s shoul-
der bottoms against the gear.

c. Turn the main drive gear over so the inner end faces

up. Align the

new

bearing with the main drive gear

and insert the installation tool with the

long side

facing down

into the bearing. Operate the press until

the tool’s shoulder bottoms against the gear.

6B. If the bearings are being installed without the installa-
tion tool, use a suitable mandrel to press in the bearing to
the depth recorded in Step 2.
7. Install a

new

oil seal (Figure 102) into the clutch side

of the main drive gear.

Mainshaft bearing

The left side mainshaft bearing (5, Figure 97) is

pressed into the transmission case. If the transmission
case is installed in the frame, a transmission main bearing
remover set (JIMS part No. 1720) (Figure 105), or equiv-
alent, is required to remove the main drive gear bearing. If
the transmission has been removed, use a press to remove
the main drive gear bearing.

Whenever the main drive gear is removed, the

mainshaft drive gear bearing is damaged and must be re-
placed at the same time.

CAUTION

Failure to use the correct tools to install the
bearing will cause premature failure of the
bearing and related parts.

1. Remove the main drive gear from the transmission
case as described in this chapter.
2. Assemble the special tool set onto the mainshaft bear-
ing following the manufacturer’s instructions. Then
tighten the bolt and nut slowly to pull the mainshaft bear-
ing from the transmission case.
3. Clean the bearing bore and dry it with compressed air.
Check the bore for nicks or burrs. Check the snap ring
groove for damage.

NOTE

Install the bearing into the transmission
case with the bearing manufacturer’s name
and size code facing out.

4. Apply transmission oil to the bearing bore in the trans-
mission case and to the outer surface of the bearing. Also
apply oil to the nut and threaded shaft of the installer tool.

5. Install the bearing onto the installation tool and assem-
ble the installation tool following the manufacturer’s in-
structions.

6. Slowly tighten the puller nut to pull the bearing into the
transmission case. Continue until the bearing bottoms in
the case.

7. Disassemble and remove the installation tool.

256

CHAPTER SIX

104

105

106

45

!

45

!

Installation

1. Replace the mainshaft bearing and oil seal as described
in the previous procedure.

2. Install a

new

snap ring with the flat side facing the

bearing.

3. Position the snap ring with the open end facing the rear
of the transmission and within a 45

!

angle to horizontal

(Figure 106). Make sure it is fully seated in the snap ring
groove.

4. Install the

new

oil seal into the case so its closed side

faces out.

5. Apply transmission oil to the bearing bore and to the
outer surface of the main drive gear. Also apply oil to the
nut and threaded shaft of the installer tool.

6. Insert the mainshaft into the mainshaft bearing as far as
it will go. Hold it in place and assemble the special tool
onto the main drive gear and transmission case following
the manufacturer’s instructions.

7. Slowly tighten the puller nut to pull the main drive gear
into the bearing in the transmission case. Continue until
the gear bottoms in the bearings inner race.

8. Disassemble and remove the installation tool.

9. Install the spacer into the main drive gear oil seal.

10. Install the transmission shaft assemblies from the
transmission case as described in this chapter.

TRANSMISSION CLUTCH RELEASE

MECHANISM COVER

Removal

1. Remove the exhaust system as described in Chapter
Seven.
2. Drain the transmission oil as described in Chapter
Three.

NOTE

If the cover is difficult to remove, apply the
clutch lever after the mounting bolts have
been removed. This will usually break the
cover loose.

3. Remove the release cover mounting bolts, the side
cover and the gasket. Do not lose the locating dowels.
4. At the clutch cable in-line adjuster, perform the follow-
ing:

a. Remove the clamp (A, Figure 107) and slide the

rubber boot (B) off the clutch in-line cable adjuster.

b. Loosen the adjuster locknut (A, Figure 108) and turn

the adjuster (B) to provide maximum cable slack.

Disassembly

Refer to Figure 109.

NOTE

Before removing the snap ring in Step 1,
note the position of the snap ring opening.
The snap ring must be reinstalled with its
opening in the same position.

1. Remove the snap ring (A, Figure 110) from the groove
in the side cover.
2. Lift the inner ramp (A, Figure 111) out of the cover
and disconnect it from the clutch cable coupling (B).
3. Remove the clutch cable coupling (A, Figure 112).
4. Remove the inner ramp and balls (B, Figure 112).
5. If necessary, remove the clutch cable (B, Figure 110)
from the side cover.

Inspection

1. Clean the side cover and all components thoroughly in
solvent and dry them with compressed air.

TRANSMISSION

257

6

108

107

2. Check the release mechanism balls and ramp ball
sockets for cracks, deep scoring or excessive wear (Fig-
ure 113).
3. Check the side cover (Figure 114) for cracks or dam-
age. Check the clutch cable threads and the coupling snap
ring groove for damage. Check the ramp bore in the side
cover for excessive wear, or lips or grooves that could
catch the ramps and bind them sideways, causing im-
proper clutch adjustment.
4. Replace the clutch cable O-ring if it is damaged.
5. Replace all worn or damaged parts.

Assembly

1. If removed, screw the clutch cable into the side cover.
Do not tighten the cable fitting at this time.
2. Install the inner ramp and balls (B, Figure 112). Center
a ball into each socket.
3. Install the clutch cable coupling onto the clutch cable
as shown in A, Figure 112.
4. Connect the inner ramp onto the clutch cable coupling
(B, Figure 111).
5. Align the inner ramp socket with the balls and install
the inner ramp as shown in Figure 115.
6. Install the snap ring into the side cover groove. Posi-
tion the snap ring so its opening faces to the right of the
outer ramp tang slot as shown in A, Figure 110. Make
sure the snap ring is seated correctly in the groove.

258

CHAPTER SIX

110

109

CLUTCH RELEASE

ASSEMBLY

1. Clutch release cover
2. Ramp coupling
3. Outer ramp
4. Balls (3)

111

112

113

5. Inner ramp
6. Snap ring
7. Gasket

Installation

1. If removed, install the locating dowels.

2. Install a

new

gasket.

3. Install the release cover and bolts. Tighten the bolts in
a crisscross pattern to 84-108 in.-lb. (9-12 N•m).

4. Refill the transmission with oil as described in Chapter
Three.

5. Install the exhaust system as described in Chapter
Seven.

6. Adjust the clutch as described in Chapter Three.

TRANSMISSION DRIVE SPROCKET

Removal/Installation

NOTE

The mainshaft bearing race does not need to
be removed for the transmission drive
sprocket to be removed.

1. Remove the primary chain case assembly as described
in Chapter Five.

2. If necessary, install a sprocket locker tool (JIMS part
No. 2260) (Figure 116) onto the transmission drive
sprocket following the manufacturer’s instructions.

3. Remove the two Allen bolts and the lock plate (Figure
117).

4A. Shift the transmission into gear.

4B. If the drive belt is still in place, have an assistant apply
the rear brake.

5. Use a countershaft sprocket nut wrench (JIMS part No.
946600-37A) to install the inner collar (Figure 118) onto
the mainshaft.

CAUTION

The sprocket nut has left-hand threads. Turn
the tool

clockwise

to loosen it in Step 6.

TRANSMISSION

259

6

114

115

116

117

118

6. Install the wrench onto the nut (Figure 119) and turn it

clockwise

to loosen the nut.

7. Remove the special tools and the nut from the
mainshaft.
8. Carefully remove the transmission drive sprocket from
the mainshaft. Do not damage the bearing race.
9. Install by reversing these removal steps. Note the fol-
lowing:

a. Use the same tool set up used during removal.
b. Apply Loctite TB1360 or an equivalent to the nut

and Allen bolts prior to installation.

c. Position the nut with the flanged side facing the

drive sprocket.

CAUTION

In substep d, do not tighten the nut past an
additional 45

!

to align the lock plate bolt

holes or the nut will be damaged.

d. Tighten the nut

counterclockwise

to 50 ft.-lb. (68

N•m). Then tighten it an additional 30

!

until the

lock plate holes are aligned.

TRANSMISSION CASE

Only remove the transmission case (Figure 58) if it re-

quires replacement or to perform extensive frame repair
or replace the frame. All internal transmission compo-
nents can be removed with the case in the frame.

Removal/Installation

1. Drain the transmission oil and primary chain case lu-
bricant as described in Chapter Three.
2. Remove the exhaust system as described in Chapter
Seven.
3. Remove the primary chaincase cover (A, Figure 120)
as described in Chapter Five.
4. Remove the clutch assembly as described in Chapter
Five.
5. Remove the transmission side cover and clutch release
mechanism as described in this chapter.
6. Remove the primary chaincase housing as described in
Chapter Five.
7. Remove the oil tank and oil lines (A, Figure 121) as
described in Chapter Four.
8. Remove the transmission drive sprocket as described
in this chapter.
9. Remove the transmission shaft assemblies as de-
scribed in this chapter.
10. Remove the external shift linkage as described in this
chapter.

11. Make an alignment mark on the shift rod lever and the
end of the shift shaft.

12. Remove the clamp bolt (A, Figure 122) securing the
shift rod lever (B).

13. Use a T50 Torx wrench to back the centering screw
(A, Figure 123) out until it clears the centering slot in the
shift pawl assembly.

14. Remove the snap ring (B, Figure 123) and flat
washer (C) from the shift shaft (D).

260

CHAPTER SIX

119

120

121

15. Remove the swing arm as described in Chapter
Twelve.

16. On California models, remove the charcoal canister
as described in Chapter Seven.

17. Remove the starter as described in Chapter Eight.

18. Support the transmission case with a jack or wooden
blocks. Apply sufficient jack pressure on the transmission
prior to removing the engine-to-transmission mounting
bolts.

NOTE

Figure 120

shows only the upper mounting

bolt, remove the lower bolt also.

19. Remove the two bolts and washers on each side se-
curing the transmission to the engine. Refer to B, Figure
121 and B, Figure 120.
20. Move the transmission case to the rear to clear the
two lower locating dowels.
21. Move the transmission toward the right side and re-
move the transmission case from the frame.
22. Install the transmission case by reversing these re-
moval steps. Note the following:

a. Make sure the two locating dowels are in place on

the engine or transmission case (Figure 124).

b. Tighten the transmission mounting bolts in a criss-

cross pattern to a preliminary torque of 15 ft.-lb. (20
N•m).

c. Continue to tighten the mounting bolts in a criss-

cross pattern to 30-35 ft.-lb. (41-48 N•m).

TRANSMISSION

261

6

123

124

122

Tables 1-3 are on the following pages.

Table 1 TRANSMISSION GENERAL SPECIFICATIONS

Item

Specification

Transmission type

Five-speed, constant mesh

Gear ratios

First

3.21

Second

2.21

Third

1.57

Fourth

1.23

Fifth

1.00

Transmission fluid capacity

Oil change

20-24 U.S. oz. (591-709 ml)

Rebuild (dry)

24 U.S. oz. (709 ml)

Table 2 TRANSMISSION SERVICE SPECIFICATIONS

Item

in.

mm

Countershaft

Runout

0.000-0.003

0.00-0.08

Endplay

None

First gear

Clearance

0.003-0.0019

0.080-0.048

End play

0.005-0.0039

0.127-0.099

Second gear

Clearance

0.003-0.0019

0.008-0.048

End play

0.005-0.0440

0.127-1.118

Third gear

Clearance

0.000-0.0080

0.000-0.0203

Fourth gear

Clearance

0.000-0.0080

0.000-0.0203

End play

0.005-0.0390

0.127-0.991

Fifth gear

Clearance

0.000-0.0080

0.000-0.0203

End play

0.005-0.0400

0.127-0.102

Mainshaft

Runout

0.00-0.003

0.00-0.08

Endplay

None

First gear

Clearance

0.000-0.0080

0.000-0.203

Second gear

Clearance

0.000-0.0800

0.000-2.032

Third gear

Clearance

0.003-0.0019

0.008-0.048

End play

0.005-0.0420

0.127-1.067

Fourth gear

Clearance

0.0003-0.0019

0.008-0.048

End play

0.005-0.0310

0.127-0.787

Main drive gear (fifth)

Bearing fit in transmission case

0.0003-0.0017

0.0076-0.043

Fit in bearing

Tight fit

0.0009

0.023

Loose fit

0.0001

0.0025

Fit on mainshaft

0.0001-0.0009

0.0025-0.023

End play

None

Shifter cam assembly

Right edge of middle cam groove

to right support block distance

1.992-2.002

50.60-50.85

Shifter cam end play

0.001-0.004

0.025-0.10

262

CHAPTER SIX

(continued)

Table 2 TRANSMISSION SERVICE SPECIFICATIONS (continued)

Item

in. mm

Shifter forks

Shifter fork-to-cam groove end play

0.0017-0.0019

0.043-0.048

Shifter fork-to-gear groove end play

0.0010-0.0011

0.025-0.0279

Shift fork finger thickness

0.165

4.19

Side door bearing

Fit in side door

0.0014-0.0001

0.036-0.0025

Fit on countershaft

Tight fit

0.0007

0.018

Loose fit

0.0001

0.0025

Fit on mainshaft

Tight fit

0.0007

0.018

Loose fit

0.001

0.025

Table 3 TRANSMISSION TORQUE SPECIFICATIONS

Item

ft.-lb.

in.-lb.

N•m

Clutch cable fitting

–

30-60

3-7

Clutch release cover bolts

–

84-108

9-12

Shift rod lever clamp bolt

18-22

–

24-30

Shift rod locknuts

20-24

–

27-32

Shift cam support block bolts

–

84-108

9-12

Transmission top cover bolts

–

84-108

9-12

Transmission main and countershaft

locknuts at side door

45-55

–

61-75

Transmission case door

1/4 in. fasteners

–

84-108

9-12

5/16 in. fasteners

13-16

–

18-22

Transmission drain plug

14-21

–

19-28

Engine-to-transmission bolts

Preliminary

15

–

20

Final

30-35

–

41-48

Detent follower bolt

–

84-108

9-12

Transmission drive sprocket

Mounting nut*

50

–

68

Lockplate bolts

–

84-108

9-12

*Tighten an additional 30

!

–not to exceed 45

!

.

TRANSMISSION

263

6

CHAPTER SEVEN

FUEL, EXHAUST AND

EMISSION CONTROL SYSTEMS

This chapter includes procedures for the fuel, exhaust

and emission control systems (California models). Elec-
tronic fuel injection (EFI) models are also covered. Rou-
tine air filter maintenance is described in Chapter Three.
Specifications and carburetor jet sizes are in Tables 1-3 at
the end of the chapter.

WARNING

Gasoline is carcinogenic and extremely
flammable, and must be handled carefully.
Wear latex gloves to avoid skin contact. If
gasoline does contact skin, immediately and
thoroughly wash the area with soap and
warm water.

AIR FILTER BACKPLATE

Removal

Refer to Figure 1 and Figure 2.

1. Remove the air filter cover screw (A, Figure 3) and re-
move the cover (B).

2. Remove the Torx screws and bracket (Figure 4, typi-
cal) from the air filter element.

3. Gently pull the air filter element away from the
backplate and disconnect the two breather hoses (A, Fig-
ure 5) from the hollow bolts on the backplate. Remove the
air filter element (B, Figure 5).

4. Unscrew and remove the breather hollow bolts (A,
Figure 6) securing the backplate to the cylinder heads.

5A. On California carbureted models, pull the backplate
(B, Figure 6) partially away from the cylinder heads and
the carburetor, then disconnect the evaporation emission
control clean air inlet hose (Figure 7).

5B. On all other models, pull the backplate (B, Figure 6)
away from the cylinder heads and remove it.

6. Remove the carburetor or fuel injection module gasket
from the air filter, the backing plate or the fuel injection
module (Figure 8).

Inspection

1. Inspect the backplate for damage.

2. On California models, make sure the trap door swings
freely (Figure 9).

3. Make sure the breather hollow bolts and breather hoses
(Figure 10) are clear. Clean them out if necessary.

NO

TE:

Ref

er t

o th

e S

upp

lem

ent

at

the

bac

k o

f th

is m

anu

al f

or

info

rma

tion

uni

que

to 2

004

-20

05

mo

del

s,

inc

lud

ing

Scr

eam

in’

Eag

le m

ode

ls.

Installation

1. Apply a couple dabs of gasket sealer to the

new

gasket

and install it onto the air filter, the backing plate or the fuel
injection module (Figure 8).

2. Move the backplate into position.

3. On California carbureted models, move the backplate
part way into position. Connect the evaporation emission
control clean air inlet hose (Figure 7) to the fitting on the
backside of the backplate.

4. Position the backplate (B, Figure 6) against the carbu-
retor, or fuel injection module, and cylinder heads. Make
sure the Torx bolt holes of the gasket and backplate are
aligned with the carburetor or fuel injection module. Re-
position the gasket if necessary.

5. Install the breather hollow bolts (A, Figure 6) securing
the backplate to the cylinder heads. Tighten them to
120-144 in.-lb. (14-16 N•m).
6. Position the element (B, Figure 5) with the flat side
facing down and attach the breather hoses (A) to the back-
side of the element.

NOTE

If an aftermarket air filter element is being
installed, position it onto the backplate fol-
lowing the manufacturer’s instructions.

7. Move the element into position and install the mount-
ing bracket (Figure 4) and the Torx screws. Tighten the
Torx screws to 20-40 in.-lb. (2-4 N•m).
8. Apply a drop of ThreeBond TB1342 (blue) or an
equivalent threadlocking compound to the cover screw
prior to installation.

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

265

7

1

AIR FILTER

(CARBURETED MODELS)

1. Backplate (California)
2. Gasket
3. O-ring
4. Gasket
5. Breather hollow bolt
6. Breather hose
7. Gasket
8. Air filter
9. Torx screw

10. Mounting bracket
11. Backing plate (other than

California and HDI models)

12. Backing plate (HDI models)
13. Seal (California models)
14. Cover (California models)
15. Trim plate
16. Screw
17. Seal (other than

California models)

18. Cover (other than

California models)

9. Inspect the seal ring (Figure 11) on the air filter cover
for hardness or deterioration. Replace it if necessary.

10. Install the air filter cover (B, Figure 3) and the screw
(A). Tighten the screw to 36-60 in.-lb. (4-7 N•m).

CARBURETOR

Operation

An understanding of the function of each of the carbure-

tor components and their relation to one another is a valu-
able aid for pinpointing the source of carburetor trouble.

266

CHAPTER SEVEN

2

1. Torx screws
2. Mounting bracket
3. Air filter
4. Breather hose
5. Breather hollow bolt
6. Gasket
7. O-ring

AIR FILTER (EFI MODELS)

8. Gasket
9. Backing plate (other than HDI models)

10. Trim plate
11. Screw
12. Cover
13. Seal
14. Backing plate (HDI models)

3

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

267

7

5

6

7

8

9

4

10

11

The carburetor’s purpose is to supply and atomize fuel,

and mix it in correct proportions with the air drawn in
through the air intake. At the primary throttle opening
(idle), a small amount of fuel is siphoned through the pilot
jet by the incoming air. As the throttle is opened further,
the air stream begins to siphon fuel through the main jet
and needle jet. The tapered needle increases the effective
flow capacity of the needle jet as it is lifted, and occupies
progressively less of the area of the jet. At full throttle, the
carburetor venturi is fully open and the needle is lifted far
enough to permit the main jet to flow at full capacity.

The choke circuit is a starting enrichment valve system.

The choke knob under the fuel tank on the left side of the
engine opens an enrichment valve; rather than closing a
butterfly in the venturi area as on some carburetors. In the
open position, the slow jet discharges a stream of fuel into
the carburetor venturi to enrich the mixture when the en-
gine is cold.

The accelerator pump circuit reduces engine hesitation

by injecting a fine spray of fuel into the carburetor intake
passage during sudden acceleration.

Removal

1. Remove the air filter and backplate as described in this
chapter.

2. Remove the fuel tank as described in this chapter.

3. Loosen the locknut (A, Figure 12, typical) and discon-
nect the starting enrichment valve cable from the mount-
ing bracket (B, Figure 12, typical). Move the end of the
cable out of the mounting bracket.

4. Roll the rubber boots (Figure 13) off the throttle cable
adjusters.

5. At the handlebar, loosen both control cable adjuster
locknuts (A, Figure 14), then turn the cable adjusters (B)

clockwise

as far as possible to increase cable slack.

6. There are two different throttle cables. Label the two
cables at the carburetor before disconnecting them. One is
the throttle control cable (A, Figure 15) and the other is
the idle control cable (B).

7. Disconnect the fuel supply hose (Figure 16) from the
carburetor fitting.

8. Twist and pull the carburetor off the seal ring and in-
take manifold.

9. Disconnect the vacuum hose from the carburetor fit-
ting.

10. Disconnect the throttle control cable (A, Figure 17)
and the idle control cable (B) from the carburetor cable
guide and the throttle wheel.

11. Drain the gasoline from the carburetor assembly.

268

CHAPTER SEVEN

12

13

14

15

12. Inspect the carburetor seal ring on the intake mani-
fold for wear, hardness, cracks or other damage. Replace
it if necessary.
13. If necessary, service the intake manifold as described
under

Intake Manifold

in this chapter.

14. Cover the intake manifold opening.

Installation

1. If removed, seat the seal ring onto the intake manifold.
Make sure it is correctly seated to avoid a vacuum leak.
2. Route the starting enrichment valve cable between the
cylinders and toward its mounting bracket on the left side.
3. Connect the idle cable to the carburetor as follows:

a. The idle cable has the small spring (A, Figure 18)

on the end of the cable.

b. Insert the idle cable sheath into the rear cable

bracket guide on the carburetor (B, Figure 18).

c. Attach the end of the idle cable to the throttle wheel

(C, Figure 18).

4. Connect the throttle cable to the carburetor as follows:

a. Insert the throttle cable sheath into the front cable

bracket guide on the carburetor.

b. Attach the end of the throttle cable to the throttle

wheel.

5. Operate the hand throttle a few times. Make sure the
throttle wheel operates smoothly with no binding. Also
make sure both cable ends are seated squarely in their ca-
ble bracket guides and in the throttle wheel.

CAUTION

The carburetor must fit squarely onto the in-
take manifold. If it is misaligned, it may
damage the intake manifold seal ring, re-
sulting in a vacuum leak.

6. Align the carburetor squarely with the intake manifold
(Figure 19), then push it into the manifold until it bot-
toms. Position the carburetor so it sits square and vertical
with the manifold.
7. Connect the vacuum hose to the carburetor fitting.
Make sure it is seated correctly.
8. Slide a

new

hose clamp over the fuel supply hose, then

connect the fuel hose to the hose fitting on the carburetor
(Figure 16).
9. Insert the starting enrichment valve cable into the
mounting bracket (B, Figure 12), then tighten the locknut
(A) securely.
10. Before installing the fuel tank, recheck the idle and
throttle cable operation. Open and release the hand throt-
tle. Make sure the carburetor throttle valve opens and
closes smoothly. Make sure both cables are routed prop-

FUEL, EXHAUST AND EMISSION CONTROL SYSTEMS

269

7

16

17

18

19