Harley-Davidson 77197-07 - Manual (Page 3)

NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the lower switch housing is turned upside down or
shaken.
5. See Figure 5. Remove the brass ferrules from the notches
on the inboard side of the throttle control grip, then remove
ferrules from the cable end fittings. Save ferrules for re-
installation.
3
4
5
2
1
is02724
1. Throttle cable
2. Idle cable
3. Groove
4. Notch
5. Ferrule
Figure 5. Remove Throttle and Idle Control Cables
NOTE
It is not necessary to remove the throttle control grip.
6. See Figure 6. Pull the crimped inserts at the end of the
throttle and idle control cable housings from the lower
switch housing. For best results, use a rocking motion
while pulling. Place a drop of light oil on the retaining rings,
if necessary. Save inserts for re-installation.
7. Remove the cables from the switch housing, then separate
the upper and lower switch halves.
8. Follow the instructions in applicable Service Manual and
remove windshield and nacelle.
NOTE
When performing the next Step, the right side Molex Electrical
Connectors are Black; the left side Molex Electrical Connectors
are Grey.
1
3
2
4
is02725
1. Lower cable housing
2. Idle cable insert (gold)
3. Tension adjuster screw
4. Throttle cable insert (silver)
Figure 6. Upper Right Handlebar Switch Housing
9. Trace the right handlebar wiring harness to the 6-place
Molex connector and disconnect connector halves. Note
the existing harness routing and cable ties securing har-
ness to handlebars. Remove and discard the right hand
control and harness assembly.
10. See Figure 10. Obtain the new Right Handlebar Control
and Harness Assembly (2) from kit. Install the new harness
6-place connector in same place as connector removed
in Step 9. Locate the unused 3-place connector half (next
to the 6-place) and install the 4-Place connector from the
new harness to the 4-place connector in headlamp
assembly.
11. At new handlebar control assembly, hold the lower switch
housing with concave side facing upward. Install the ten-
sion adjuster screw and spring with the friction shoe (saved
from Step 4) so that pin hole is over the point of the Ten-
sion adjuster screw. Adjust the tension adjuster two or
three turns to hold assembly in place.
NOTE
The friction shoe is a loose fit and may fall out or become dis-
lodged if the switch housing is turned upside down or shaken.
12. Refer to Figure 6. Push the throttle and idle control cables
into the lower switch housing until they snap into place.
Perform the following:
a. Obtain the crimped inserts removed in Step 6. Note
the different diameter inserts crimped into the end of
the throttle and idle control cable housings.
b. Push the larger diameter insert (silver) on the throttle
cable housing into the larger hole in front of the ten-
sion adjuster screw.
c. Push the smaller diameter insert (gold) on the idle
cable housing into the smaller hole at the rear of the
tension adjuster screw.
NOTE
To aid assembly, place a drop of light oil on the retaining rings
of the crimped inserts. Always replace the retaining rings if
damaged or distorted.
13. Slide the throttle control grip towards motorcycle until it
bottoms against the closed end of the handlebar. Rotate
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