Installation Instructions: OFC Gas Grip Made in Germany
Innovations: 2 gas cables installed in the handlebars Maintenance-free For universal use* Use of top-quality materials Long service life 6 bearings (needle+roller bearings) Extremely free-moving Easier and quicker gas cable exchange No pre-assembled gas cables required (material sold by the meter can be used) One design for installation with or without handlebar end flashers No "uncontrolled opening of the throttle" when turning the handlebars to their full extent Incl. cable tensioner for both gas cables Incl. 2 "special" gas cables (Teflon-coated) * for all makes of motorcycle with inch handlebars with cable passage
Dear Customer, Thank you for purchasing this product. Please read these installation instructions carefully in full, before you decide whether to carry out the installation yourself or have it carried out by a specialist. If you have any questions or suggestions or if you require a spare part, send us an email (info@ostfreesenchoppers.com) or call us on (+49 4934 / 80 67 326) Component overview OFC gas grip OFC cable tensioner Teile-Nr.: Teilebenennung: Anzahl: 1 Grip piece 1 2 Twin-screw 1 3 End piece 1 4 Receiving bush 1 5 Guide tube 1 6 Sliding piece 2 7 Needle bearing 2 8 Ball bearing 4 9 Washer 4 10 Grub screw 2 11 Oval head screw 2 12 Grub screw 1 13 Countersunk screw 2 14 Base body: cable tensioner 1 15 Set screw: cable tensioner 2 16 Lock nut: cable tensioner 2
Safety information! Changes need to be made to the handlebars for installation of the twistable gas grip for operating two internal gas cables. Special tools and technical skill are required for this. If in doubt, have the installation carried out by a specialist workshop! Remember: It concerns your safety! Carefully read through these installation instructions before installation/use of the gas grip and follow them meticulously step by step. Liability and warranty claims become invalid in the event of incorrect installation and failure to follow the installation instructions. Only use Teflon cables and stainless steel cores for the gas cables and avoid kinks during the installation, in order to ensure optimum functioning! As a result of the large number of handlebars available on the market and the resulting differences in the internal handlebar diameters, the grip may only fit in the handlebars with difficulty or not at all in some cases. It can be adapted by screwing off the front grip piece (1). This does not affect the warranty, provided that the work is carried out in line with good professional practice and the minimum diameter of 20mm is complied with! Requisite tools! Vice/machine vice Centre punch Scribe Felt tip pen/edding pen Hammer Steel drill bit Ø 5mm Hacksaw Dremel/deburring tool Side cutters Caliper gauge Drill/box column drill Medium-sized round and flat file (cut 3) 90 counterbore Ø approx. 10 mm Threadlock adhesive, medium-strength (e.g. Loctite ) Hex key set from 1.5-10mm Lathe We recommend our assembly tool for fitting the handlebars Article no.: OFC-001a (not supplied) We recommend our assembly tool for assembly/disassembly of the receiving bush (4) Article no.: OFC-001b (not supplied)
Before beginning the installation! Requirements for installation: Use handlebars with a cable passage ❶ The start of the groove for mounting the fitting must be at least 150 mm from the right-hand end of the handlebars. Since the twistable gas grip for operating two internal gas cables has the same outside diameter as the standard plastic rotating sleeve of Harley-Davidson, the original grips can normally still be used. However, we recommend our OFC-grips "Old School", Article no.: OFC-005 or "Custom" Article no.: OFC-006 (not supplied) ❷ ❶ Cable passage ❷ 1. Preparation of the handlebars for installation Preparation without assembly tool: Article no.: OFC-001a Carefully clamp the right-hand end of the previously disassembled or new handlebars in a bench vice with a cloth (or with "soft jaws" if available), so that at least 120mm protrudes. Mark the dimension 120mm at the right-hand end of the handlebars with the aid of the Edding pen, the scribe and the caliper gauge. Cut or saw the handlebars off at the marked position. Important: When sawing, ensure that the cut is as straight as possible! Carefully deburr the end of the handlebars with the files/dremel. Some handlebars have a welded seam in the handlebar tube. This must be smoothed to a depth of 35mm with the Dremel. Take the handlebars and mark the underside of the right-hand handlebar end with an Edding pen, so that the two fixing screws are located beneath the handlebars after they have been installed and are not visible. Clamp the handlebars in the vice, so that the marking points upwards. Mark the exact dimensions, 10mm and 25mm ❸ for the two fixing holes at the end of the handlebars with the scribe, and center-punch the subsequent drill holes in the center of the underside of the right-hand end of the handlebar. Important: Please be very careful when doing this, otherwise the drill holes will not be in line with the threaded holes in the grip! Take the handlebars and clamp them in a machine vice if possible and drill two 5mm holes at the previously center-punched positions using a box column drill. Countersink the two holes until the supplied M5 countersunk-head screws fit in the countersinks. Reassemble the handlebars on your motorcycle. ❸
2. Preparation of the grips for installation Measure the internal diameter of the handlebars. The diameter of the grip piece (1) must be approx. 0.02 0.05mm smaller than the internal handlebar diameter. If required, use a lathe to turn the grip piece (1) incl. end piece (3) to the appropriate diameter.❹ Care must be taken that the minimum diameter of 20mm is complied with! Please note that the twistable gas grip for operating two internal gas cables has to be disassembled for this. Refer to the component overview (page 2). The grip can be reassembled after the turning. Ensure that all the screw connections are fully tightened, especially that of the receiving bush (4)! Use threadlock adhesive ("medium-strength"), e.g. of the brand Loctite, on all threaded screw connections! ❹ Turn grip piece incl. end piece to internal diameter of handlebars! 3. Installation of a handlebar end flasher (only when using handlebar end flashers) Push your grip rubber/aluminum grip over the handlebars before you start assembling the handlebar end flasher. Pass the cable provided for the handlebar end flasher through the handlebars first of all and then through the center drill hole of the end piece (3), until it projects at the end of the receiving bush (4).❺ Take 2 suitable shrink-on tube ends and place over them over the inserted cable ends and then solder the cable ends to the ends of the handlebar end flasher cable. Please also carefully read through the installation instructions of the handlebar end flasher manufacturer! Now you can push the two shrink-on tube ends over the soldering points and shrink-wrap with a hot-air gun. The handlebar end flasher can then be inserted in the receiving bush (4) ❻ Ensure that cable is always pulled along, so that it is passed through with a perfect fit and does not stick! ❺ Centre drill hole for handlebar end flasher cable ❻
4. Montage der beiden Gaszüge Push your grip rubber/aluminum grip over the handlebars and mount the supplied cable tensioner for both gas cables near the carburetor before you start assembling the two gas cables! ❼ (Recommended). A bracket should be made for this if required! Cut the two gas cable casings which run from the carburetor to the cable tensioner to size and insert them ❽. Next cut the two gas cable casings which run from the cable tensioner to the handlebar end to size and insert them. ❾ Ensure that the "Teflon" channel is free after cutting the gas cable casings to size. Enlarge with a small needle if necessary!! Push the gas cable from the carburetor side through the gas cable casing up to the handlebar end, so that a short end which fits in the grip piece protrudes. ❿ Fix a screwed nipple suitable for your carburetor to the gas cable and hook it in the carburetor. Pass the gas cable into the drill hole provided in the end piece (3) of the gas grip. Ensure that the sliding piece (6) for the gas cable is at its limit in the front position (Sliding piece (6) rests on the end piece (3)). Push the gas cable all the way into the sliding piece (6) (the limit stop in the sliding piece is clearly felt) and tighten the grub screw (10) for clamping the gas cable fingertight with a 1.5mm hex key. (Tightening torque 2.5Nm) ⓫ Repeat these steps for the return cable. ⓬ Insert two gas cable casings in the holes provided in the end piece (3) ⓭and then carefully push the gas grip into the handlebars. Ensure that the handlebar end flasher cable (if present) is always pulled along, so that it is passed through with a perfect fit and does not stick and the two ends of the gas cable casings remain in the holes provided in the end piece (3)! Screw the gas grip tightly in the handlebars by means of the two supplied M5 countersunk-head screws (13). Use threadlock adhesive ("medium-strength"), e.g. of the brand Loctite, when screwing in the M5 countersunk-head screws! You can eliminate the "residual play" of the cables by means of the set screws (16) on the cable tensioner and fix them with the lock nuts (17). The screwed nipples should be "readjusted" in the event of excessive "residual play"! We congratulate you on the installation of the OFC gas grip and wish you a pleasant and safe journey wherever the road takes you The OFC Team ❽ ❼ ❾
❿ Grub screw (10) for cable clamping Sliding piece 6 is at its limit (Ball bearing in forward position!) ⓫ ⓬ Grub screw (10) for cable clamping Sliding piece 6 is at its limit(ball bearing in forward position!) ⓭ Holes for gas cable casings
1. Assembly tool for fitting the handlebars Article no.: OFC-001a Zubehör 2. Assembly/disassembly tool for assembling/disassembling the receiving bush (4) Article no.: OFC-001b 3. OFC "Custom" grip Article no.: OFC-006 4. OFC "Old School" grip Article no.: OFC-005 5. Gas cable with Teflon inner core Article no.: OFC-001c Please note A TÜV or general type approval is not required for installation of the OFC gas grip.however, we recommend an individual inspection for entry in the vehicle documents!