INSTALLATION INSTRUCTIONS, HARLEY & AMERICAN CUSTOM V-TWINS

1.      Loosen throttle return cable adjusting jam nut and back off cable adjusting nut (fig 1).

2.      Install a 5/32 cardboard shim in brake lever as shown in (fig. 2).

                 a. This step is important to avoid damaging the brake light switch.

3.      Remove the 4 bolts that secure master cylinder and switch housing to handlebar (fig. 3). Gently lower front brake master cylinder and brake lever away from handlebar being careful not to bend or crimp front brake line.

4.      Separate top half of switch housing from bottom half (fig. 4) being very careful not to put strain on wiring inside switch housing

5.      Remove cables from grip (fig 5) being very careful not to loose brass cable end ferrules.

6.      Remove both cables from switch assembly.

a.      Applying a small of oil (we use WD 40) around cable end inside switch housing cavity and wiggling cable while gently pulling down will help remove cable from switch assembly.

7.      Remove throttle lock plastic friction shoe from inside lower switch assembly (fig.6).

8.      Remove “C” clip from thumbscrew stud (fig. 7).

9.      Remove thumbscrew from switch housing.

The next two steps involve enlarging the original thumbscrew hole. We STRONGLY recommend using our drill jig (included with Cruise-Mate kit) to drill and tap your switch housing. 

Drilling and tapping the new hole incorrectly is likely to cause CRUISE-MATE to operate incorrectly making proper adjustment impossible and may cause throttle to lock unexpectedly causing serious injury or death.

 10. Insert ¼ bolt in the other hole in drill jig. Install plastic spacer between jig and switch housing, install washer and nut and hand tighten (fig. 8).

a. The two cable holes in housing are different sizes, ¼ inch bolt will only fit in the front hole of housing.

11. Install alignment pin in drill jig bushing and push into original thumbscrew hole in lower switch housing (fig 9) and tighten jig bolt wrench tight.

12. Remove alignment pin from drill jig and drill original hole with 21/64-drill bit (fig. 10).

13. Remove aluminum bushing from drill jig and using hole in jig to guide tap straight, tap the newly drilled hole with 3/8-24 tap (fig. 11).

CAUTION;

·        be sure to remove all metal chips from switch housing before proceeding with CRUISE-MATE installation.

15. Apply LocTite (included) to the 3/8-24 threads of stainless steel bushing on Cruise-Mate cartridge and install cartridge into the 3/8-24 threaded hole (fig. 12).

a.      Caution; over tightening bushing may strip threads in switch housing.

16. Unscrew Cruise-Mate stud until pressure is removed from spring.

17. Replace throttle cables in switch housing assembly and re-assemble switch, brake lever assembly and grip.

a.      When re-assembling brake and switch housing assemblies, ensure tab on switch housing mates with notch in brake housing assembly (fig 13).

18. Return cable-adjusting nut to original position and tighten adjuster jam nut.

19. Screw CRUISE-MATE cartridge into switch housing until you feel resistance then stop and install CRUISE-MATE handle, spring and bolt.

a.      Apply a drop of LocTite to threads of shoulder bolt to ensure bolt won’t vibrate out.

You are now ready to adjust CRUISE-MATE for operation. While adjusting it’s very possible you will flood your engine (carburetor models only) so you may have to let your bike set for a few minutes before starting engine. 

CAUTION; PERFORM ALL ADJUSTMENTS WITH ENGINE OFF. ADJUSTING CRUISE-MATE WITH ENGINE RUNNING COULD CAUSE SERIOUS DAMAGE TO ENGINE.

 1.      Move CRUISE-MATE handle all the way forward (toward front of bike), turn throttle to full open and release.

a.      If throttle will not stay in full open position when you remove your hand, go to step-2.

b.      If throttle stays in full open position when you remove your hand, go to step 6.

2.      Move CRUISE-MATE handle all the way forward (toward front of bike).

3.      Pull down on handle portion of CRUISE-MATE

a.      Pulling down will disengage the male and female spline inside CRUISE-MATE handle. 

4.      Rotate handle toward rear of bike one tooth of spline (approximately 15 °) and release handle.

a.      When turning CRUISE-MATE handle during adjustment process stud should NOT turn.

5.      Repeat steps 1 – 4 until CRUISE-MATE holds throttle at any position while on (toward front of bike) and releases throttle completely (from full open position) when CRUISE-MATE is turned off (toward rear of bike).

6.      With throttle full open turn CRUISE-MATE handle toward rear of bike.

7.      Pull down on handle portion of CRUISE-MATE

a.      Pulling down will disengage the male and female spline inside CRUISE-MATE. 

8.      Rotate handle toward front of bike one tooth of spline (approximately 15 °) and release handle.

a.      When turning CRUISE-MATE handle during adjustment process stud should NOT turn.

9.      Repeat steps 6 – 8 until CRUISE-MATE holds throttle at any position while on (handle toward front of bike) and releases throttle completely (from full open position) when CRUISE-MATE is turned off (handle toward rear of bike).

Cruise-Mate and Cruise-Mate II are intended for motorcycle warm up and service only. Under no condition do we recommend removing your hands from the handlebar or locking your throttle while the motorcycle is moving.

OPERATION and ADJUSTMENT PROCEDURES

Once installed, CRUISE-MATE is extremely reliable and easy to operate. Simply push lever forward (towards front of bike) and set your throttle where you want it. Push lever all the way toward rear of bike and throttle returns to normal operation.

SETTING TENSION of “CRUISE-MATE”:

With time and use, the friction pad may wear. Not to worry, CRUISE-MATE is infinitely adjustable. You can easily adjust for proper tension in a few seconds.

ADJUSTING CRUISE-MATE

Throttle doesn’t return to idle position when CRUISE-MATE lever is pointing toward rear of bike.

1.     Push CRUISE-MATE lever toward rear of bike.

2.    Pull down on CRUISE-MATE lever and rotate lever one tooth toward front of bike (clockwise direction looking at CRUISE-MATE from below).

3.     Re-test Cruise-Mate operation as described above.

4.     Repeat steps 1 thru 3 until Cruise-Mate releases control of throttle when lever is moved toward rear of bike.

Throttle doesn’t hold in position when CRUISE-MATE is pointed toward front of bike.

1.     Push CRUISE-MATE lever towards front of bike.

2.     Pull down on CRUISE-MATE lever and rotate lever one tooth toward rear of bike (counter clockwise direction looking at CRUISE-MATE from below).

3.     Re-test Cruise-Mate operation as described above

4.     Repeat steps 1 thru 3 until CRUISE-MATE holds throttle at desired position.