Download SYMTEC Snowmobile Thumb Warmer

SYMTEC Snowmobile Thumb Warmer
Hi/Low Model Installation Instructions (210003/210004)
For Polaris (pre ’95), Arctic Cat (pre ’98), Yamaha (pre ’94), Ski-Doo Tundra
210003MTi_A
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For full throttle travel, make sure sufficient lead wire slack is allowed
Proper cleaning of the throttle is critical for warmer adhesion
Do not cut or needlessly flex the warmer
Please read all instructions before beginning installation
Throttle Preparation/Warmer Attachment
If the temperature is below 60 degrees F. (18 deg C.)
remove the throttle and work indoors. Drill a 1/8" (3mm)
hole in the lower pivot arm of the throttle 1" from the
lower pivot hole (Figure 1). Clean the back of the throttle
using water or alcohol and the enclosed sandpaper. Rinse
and dry (air dry or use a cloth, not a paper product)
(contains silicones).
Tie a loose knot in warmer leads about 1 1/2" from the
warmer (knot will act as strain relief). Route the warmer
leads through the hole in the throttle (Figure 1). Remove
the paper backing from the warmer to expose adhesive.
Position carefully and press in place. DO NOT TRY TO
REPOSITION. Keeping the throttle at room temperature
for 8 hours will improve the bond (adhesive will totally
cure over first two days temperature is above 50 degrees).
Snug the knot against the hole in the throttle to leave a
slight loop between the warmer and knot. Clean and dry
top of warmer. Peel paper backing from insulation patch
and press on top of the warmer. Reinstall throttle if
necessary.
Hi/Low Switch Installation
Choose a location for the switch that is convenient and
has sufficient rear clearance for the electrical
connections. Drill a 1/2" (13mm) hole and install the
switch from the back. Leave the strain relief nut on the
switch. On the front install the Hi/Low indicator tab and
secure the switch and tab using the metal or plastic
locking nut. The amount of switch barrel protruding can
be adjusted by moving the strain relief nut.
Wire Routing and Connections (Power Circuit)
Remove the padded handlebar cushion or covering to
expose the handlebar. Slide the protective tubing over
both warmer leads until it contacts the throttle. Attach
connectors to warmer leads (Fig. 3 or 4). (Note use of
piggyback connector in lighted switch installation.) A
crimping tool is best, but a pliers will work. Route wires
to the area of the switch and secure with the supplied tie
wraps. Caution: The wire loop between the throttle and
Tie wrap
Throttle lever
Thumb warmer
Leadwires routed
through hole in lower
throttle arm
Figure 1. Throttle View
Low power
terminal
Ground
connection
Load terminal
(Thumb warmer)
High power
terminal
Figure 2. Lighted Switch
first tie wrap should be neither excessive nor too small
(Figure 1). You should be able to close the throttle fully
so wire slack is eliminated without the wires being
stressed.
Connect the resistor assembly to a regulated (lighting)
circuit using method A or B as follows (use A if the hand
warmer switch has a 1/4" tab and your sled is not a
Yamaha with factory hand warmers):
A) Strip the end of the yellow wire in the resistor
assembly and crimp on the supplied piggyback
connector. Unplug the power wire from the constant
power side of the existing hand warmer switch, slip on
the piggyback connector, and re-install the slip-on
connector on the male terminal of the piggyback
connector.
B) Locate a power wire (usually yellow) leading to a
headlight, taillight, or dash light. Using the red tap
connector, place the power wire in the continuous
channel and insert the yellow wire of the resistor
assembly (do not strip insulation) into the other
channel. Complete connection by squeezing (w/pliers)
the metal contact flush with the top of the connector.
Close the hinged cover until latched.
Wire Routing and Connections (Ground Circuit)
If the snowmobile has a) electric start or b) is equipped
for electric start, connect the ground lead from the
heater to the ground terminal at the regulator. If not,
the wire can be connected to any ground location.
Information Note: Lighting circuits are AC and
starting circuits DC. The above prevents
connecting AC and DC circuits, causing dim
lights.
Black Wire
Tap connector
Ground Circuit
(Use #10 ring
terminal)
Power Circuit (regulated)
Figure 3. Lighted Switch Connection
Thumb warmer
Black wire
Keyway
Yellow
wire
Ground circuit
(Use Ring
terminal)
Power circuit
(regulated)
Make remaining connections per Figure 4 (metal
switch) or Figures 2 and 3 (lighted switch). (Resistor is
in black lead). Reinstall handlebar pad.
Confirm complete, unrestricted throttle movement.
Thumb Warmer
Figure 4. Metal Switch Connection
Notes:
1.
2.
3.
4.
5.
If the heater does not get hot, check the electrical connections.
If the adhesive fails, let us know. We will return an adhesive chip at no cost.
Do not connect the warmer to a stock Yamaha hand warmer switch or non-regulated power
circuit. (Warmer designed to run at 12 - 13.5 volts. Yamaha factory hand warmers run in an
unregulated circuit. Warmer will get too hot.)
Caution: SINCE THE THUMB DOES NOT DETECT HEAT WELL, USE CAUTION WHEN
OPERATING THE WARMER OVER EXTENDED PERIODS OR WITH HANDLEBAR
MITTS.
For your information, resistance should be 30 +/- 4 ohms for the High circuit. Good riding!
SYMTEC, Inc.
6227 University Ave NE
Minneapolis, MN 55432
(763) 571-9193
www.symtec-inc.com
e-mail: [email protected]
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