3.3 - Speed Control, continued
ix. Place a 5/8”NF-18 jam nut on the threaded end of both bulkhead fittings protruding through the
mounting holes.
x. Attach a clevis (item 10) to the end of the cable used to attach to the transmission shift bar.
Note: In all cases the cable attachments must be threaded onto the ¼”NF-28 cable end one-quarter of an
inch(¼”). After each attachment is threaded onto the cable end its position must be secured by tightening
the jam nut against the attachment.
xi. Attach the cable end attachments to the speed control lever (item 25) and the transmission shift bar
(item 13). Reconnect the shift cable clevis to the transmission shift bar using the clevis pin. Secure
the clevis pin in the clevis with a NEW 3/32”(.093”) diameter X ¾” long PLATED cotter pin. Do not
reuse the cotter pin. Do the same for the speed shift lever if the buggy model so warrants.
xii. Tighten the two (2) 5/8”NF-18 jam nuts on the cable bulkhead fitting at the mounting hole located
near the transmission shift bar. Tighten the jam nuts so that the shift bar rests solidly against the
neutral stop bolt (item 17) when the end of the transmission shift bar where the spring attaches is
lifted up.
xiii. Tighten the two(2) 5/8”NF-18 jam nuts on the cable bulkhead fitting on the handlebar. Adjust the
nuts so that the end of the speed control lever is 3” below the bottom edge of the handlebar grip
when the transmission shift bar is against the neutral stop bolt.
I. Inspect the return spring (item 26). The return spring must have no physical damage, i.e., broken loops,
sprung coils, etc. Verify the spring overall length and outside diameter (see page 24). Replace the spring if
damaged and/or if not the correct size. If the return spring has not been replaced within the last twenty-four
(24), and/or it is 3/4” or 1” in outside diameter, replace it at this time.
DO NOT ATTEMPT TO REPAIR A
DAMAGED SPRING.
J. Install the return spring on to the eye bolt, item 19 and the transmission shift bar, item 13.
K. Inspect the extended length of the return spring with the transmission shift bar against the neutral stop bolt.
Verify that the overall extended length of this spring is 4-15/16”. Adjust the vertical position of the eyebolt
to obtain 4-15/16” overall length. Then torque the eye bolt nut to eighty (80) in. lb. See page 24.
L. Inspect the entire speed control lever, cable and spring assembly for smooth operation and the correct
position of the speed control lever.
M. Adjust shift cable 5/8”NF-18 jam nuts and/or cable attachment positions to achieve correct position of all
parts. Note: In no case should any cable attachment be threaded less than one-quarter(1/4”)on the cable
end. Tighten all hardware.
N. Spray moving ends of cable with approved lubrication.
O. Replace the Hydraulic Reservoir Cover.
SECTION 3
SERVICE
055838
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Summary of Contents for AW16-H
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