15. Install a new cable tie around the top
of the cable shroud. Tighten the cable tie
to the diameter noted during removal.
16. Slide the heat shrink tubing over the
cable tie and shroud end. Use a heat gun
to shrink the tubing.
BRAKE CABLE INNER WIRE
Removal
The cable inner wire can be replaced
without removing the cable housing.
1. Remove the battery from the battery
compartment (Chapter Seven).
2. Clip the cable ferrule from the brake
cable inner wire.
3. Turn out the anchor bolt (A, Figure 3),
and release the inner wire from the pinch
mechanism.
4. Pull the cable housing and inner wire
from the caliper barrel adjuster.
5. At the brake lever, loosen the adjuster
locknut (A, Figure 1) and turn the adjuster
barrel (B) from the brake lever.
6. Turn the barrel adjuster and the locknut
until their slots align with the slot in the
brake lever housing.
7. Pull the cable housing from the adjuster
barrel, and slide the inner wire (C, Figure 1)
from the slots in the housing, adjuster barrel
and locknut.
8. Press the brake lever toward the handle-
bar, and disconnect the inner wire end (A,
Figure 2) from the anchor (B) on the brake
lever.
9. Pull the inner wire from the cable hous-
ing until the far end emerges from the
cable housing.
4. While and assistant pulls the string, guide
the brake switch wire through the shroud,
into the frame cutout, and through the
frame downtube until the switch connec-
tor emerges from the battery compart-
ment.
5. Install the battery (Chapter Seven).
6. Untie the string from the brake lever
switch connector. Connect the switch con-
nector to its mate in the battery compart-
ment, and install the battery cap (Chapter
Seven).
7. Make sure the slots in the adjuster barrel
and the locknut align with the slot in the
brake lever housing (Figure 1).
8. Connect the end of the brake cable
inner wire (B, Figure 2) to the anchor (A) on
the brake lever.
9. Pull the cable housing, and slide the
cable inner wire (C, Figure 1) through the
slots in the brake lever, adjuster barrel (B)
and locknut (A). Seat the cable housing
ferrule into the adjuster barrel.
10. Slide the throttle or shifter onto the
handlebar end.
11. Install a grip spacer and handlebar grip
onto the handlebar end.
12. Position the throttle or shifter relative to
the handlebar grip as noted during remov-
al. Temporarily tighten the set screw.
13. Slide the brake lever so its bracket seats
against the throttle or shifter. Rotate the
brake lever to the position noted during
removal, and torque the brake lever clamp
bolt to the specification in Table 5.
14. Rotate the throttle or shifter so its barrel
rest against the brake lever. Torque the
throttle set screw or the shifter set screw to
the specification in Table 5.
Chapter Three
3-2
A
B
FIG. 2
A
B
FIG. 3
C
B
(38 pages)
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