Kuryakyn 6391 CRUISE-MATE MOTORCYCLE THROTTLE CRUISE ASSIST - Manual

23 Cedarhill Rd.
Bellingham, MA 02019
877-642-3722
INSTALLATION INSTRUCTIONS; HARLEY-DAVIDSON W / ELECTRONIC THROTTLE.
NOTE; PLEASE BE VERY CAREFUL WHEN HANDLING SMALL PARTS IN CRUISE-MATE PACKAGE, SPRING AND SHOULDER SCREW ARE
VERY HARD TO FIND IF DROPPED.
1. Install a 5/32 shim (cardboard shim or Allen wrench works fine) in brake lever as shown in (fig. 1).
a. This step is important to avoid damaging the brake light switch.
2. Remove the 2 bolts holding switch housing halves together and loosen two bolts holding master
cylinder halves to handlebar.
3. Separate top half of switch housing from bottom half, remove grip.
4. Remove throttle lock plastic friction shoe from inside lower half of switch housing (fig.2), friction shoe
not reused.
5. Remove “C” clip from thumbscrew stud (fig. 3).
6. 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.
7. Position drill jig on lower half of switch housing (fig. 4) and place longer of the two small plastic
bushings into switch housing cavity to the left of drill jig (fig 5).
8. Insert alignment pin into drill jig and screw into original threaded star wheel hole in housing, hand
tighten aluminum tap guide against switch housing, tighten drill jig bolt, then using pliers tighten
aluminum bushing approximately 1/8 turn to seat against housing.
9. Remove alignment pin and insert plastic drill guide bushing into tap guide.
10. Carefully drill original 8-32 star wheel hole to 21/64 ths (fig 6).
11. Remove plastic drill guide bushing from tap guide and carefully thread newly drilled hole to 3/8-24 (fig
7).
DRILL AND TAP HOLE FOR STOP PIN
1. Using #29 drill bit (included in kit), drill hole through housing where rear cable would be using plastic
bushing as a guide for drill bit.
2. Remove longer plastic bushing from switch housing cavity and replace it with the shorter of the two
bushings. Using 8-32 tap supplied with kit and plastic bushing as a guide for tap, thread newly drilled
hole.
a. Ensure tap goes all the way through jig and housing.
b. Be sure to remove any chips from inside housing.
3. Apply Loctite to stop pin threads and screw stop pin into 8-32 threaded hole from outside housing (fig
8).
4. Wrap stop pin with cardboard or other material to avoid scarring and use pliers to tighten pin into
housing.
12. Remove drill jig from switch housing, ensure all chips are removed from inside housing and reassemble
control assembly, ensure tab on housing mates with notch in master cylinder housing (fig 9).
13. Apply Loctite to outside threads of Cruise-Mate cartridge and screw cartridge into lower switch housing
and tighten (fig 10).
14. Screw Cruise-Mate insert in until you feel it contact the throttle sleeve.
15. Apply a drop of Loctite to handle shoulder screw and install handle, handle spring and shoulder screw
on end of Cruise-Mate insert, tighten handle screw (fig 11).
a. Handle spring is smaller on one end than the other, insert large end of spring in handle.
You are now ready to adjust CRUISE-MATE for operation. 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. See adjustment procedures
below.