Installation Instructions

Transcription

1 Instructions Created by an: Suzuki Samurai 1.3L Replacement Throttle Cable (SKU# SER-THC) Installation Instructions CAUTION: Safety glasses should be worn at all times when working with vehicles and related tools and equipment. Suggested Tools: Standard Screwdriver 12 mm Combination Wrench For additional copies of these and other instructions go to: and click on the Instructions tab.

2 Step 1 Locate the throttle cable bracket which is connected to the carburetor which is inboard from the air cleaner assembly. Step 2 Loosen the lock nut on the throttle cable using 12mm open end wrench. Step 3 Continue loosening the lock nut until the cable can be removed from the bracket. Step 4 Remove the cable from the bracket.

3 Notice: The carburetor shown in Tech Tips 5A to 5C is off the vehicle and laying on its side. This is done to give a clearer view of how to disconnect the cable from the carburetor. Step 5 Once the cable is free from the bracket, reach down and disconnect the cable from the carburetor throttle linkage. (See greater detail in the next 3 Tech Tips) Tech Tip 5A Make as much slack in the cable as possible. Tech Tip 5B Align the cable with the slot in the linkage. Tech Tip 5C Pull the cable end out of the linkage.

4 Step 6 Pull the OLD throttle cable away from the carburetor and lay it aside for now. Step 7 Position the NEW throttle cable in the same place that the OLD one was. Note: Do not connect to the bracket yet. Step 8 Reconnect the NEW throttle cable to the linkage by reversing the removal procedure shown in Tech Tips 5A to 5C. Step 9 Place the NEW throttle cable in the bracket with the nuts left loose for now.

5 Step 10 Route the other end of the NEW throttle cable in the same path as the old cable. Step 11 Pull the NEW throttle cable around behind the engine and lay it aside for now. Note: Be sure the NEW cable is routed in the exact same path as the OLD cable. Step 12 From inside the passenger compartment, pull slack in the old cable at the point where the cable passes through the bulkhead (or firewall) and disconnect it from the accelerator pedal linkage. Step 13 Using a standard screwdriver, push the cable out of the hole in the bulkhead. Note: The procedure for disconnecting the cable from the accelerator pedal is similar to the way you disconnected the cable from the carburetor.

6 Step 14 Pull the OLD cable out of the bulkhead into the engine compartment. Step 15 Completely remove the OLD cable and set it aside. Step 16 Push the NEW cable through the bulkhead and snap it into place. Note: Be sure the NEW cable is routed in the same path as the OLD cable. Step 17 Go back to the carburetor and disconnect the NEW throttle cable from the bracket. Note: This will give you enough slack to make the connection at the accelerator pedal.

7 Step 18 Connect the new cable to the accelerator linkage in reverse order of removal. Step 19 Reconnect the throttle linkage to the bracket at the carburetor. Step 20 Tighten the lock nut as tight as you can with your finger. Step 21 Tighten the lock nut using a 12mm open end wrench.

8 Step 22 Check the cable for proper Cable Play adjustment. (See next step) Step 23 Using the illustration shown above check the amount of cable play. Compare your findings to the chart shown above. If the cable play is not within specification it will need to be adjusted. Follow the instructions listed below: If the cable play is to great, loosen the lock nut and turn the adjusting nut clockwise. Then tighten the lock nut. If cable play is to small, loosen the lock nut and turn the adjusting nut counter clockwise. Then retighten the lock nut. Continue the adjustment procedure until the correct cable play is obtained.

9 Step 24 Check the execrator pedal. It should move freely through the entire pedal travel. If there is binding or excessive resistance, check that there are no kinks in the cable and that it is routed without sharp bends. Reroute or repair as needed. Congratulations! You have successfully installed the throttle cable. We hope these instructions have been helpful. If you have suggestions on how to improve these instructions (or products), please us at:

10 As always, If you experience any difficulty during the installation of this product please contact Low Range Off-Road Technical Support at M-F during regular store hours. Thank you for purchasing from Low Range Off-Road. These instructions are designed as a general installation guide. Installation of many Low Range Off-Road products require specialized skills such as metal fabrication, welding and mechanical trouble shooting. If you have any questions or are unsure about how to proceed, please contact our shop at or seek help from a competent fabricator. Using fabrication tools such as welders, torches and grinders can cause serious bodily harm and death. Please operate equipment carefully and observe proper safety procedures. Rock crawling and off-road driving are inherently dangerous activities. Some modifications will adversely affect the on-road handling characteristics of your vehicle. All products sold by Low Range Off-Road are sold for off road use only. Any other use or application is the responsibility of the purchaser and/or user. Some modifications and installation of certain aftermarket parts may under certain circumstances void your original dealer warranty. Modification of your vehicle may create dangerous conditions, which could cause roll-overs resulting in serious bodily injury or death. Buyers and users of these products hereby expressly assume all risks associated with any such modifications and use. Revised 11/19/14 Copyright 2014 Low Range Off-Road, LC All Rights Reserved