Lokar XDP-1000HT Midnight Series Duo-Pak Kit Instruction Manual

1. Introduction

This manual provides comprehensive instructions for the installation, operation, and maintenance of the Lokar XDP-1000HT Midnight Series Duo-Pak Kit. This kit is designed to provide a reliable and adjustable throttle cable system for automotive applications. Please read all instructions carefully before proceeding with installation or use.

2. Product Overview

The Lokar XDP-1000HT Midnight Series Duo-Pak Kit includes essential components for a complete throttle cable setup. It features a durable stainless steel housing and cable, designed for longevity and smooth operation. The kit is supplied with all necessary hardware for installation.

Kit Contents:

• 24" Hi-Tech Black Stainless Steel Housing Throttle Cable
• Carburetor Bracket
• Return Spring
• All necessary installation hardware

Figure 1: The Lokar XDP-1000HT Midnight Series Duo-Pak Kit. This image displays the complete kit, featuring a black braided stainless steel throttle cable coiled in the center. At one end, there are black anodized aluminum fittings connecting to a silver and brass-colored carburetor linkage with a threaded stud and nut. The other end of the cable shows similar black anodized fittings leading to a small black clevis-style connector, indicating the attachment point for the pedal or other mechanism. The overall design emphasizes durability and adjustability.

3. Setup and Installation

Installation of the Lokar XDP-1000HT kit requires mechanical aptitude and basic hand tools. Ensure the vehicle's engine is off and cool before beginning. Refer to your vehicle's service manual for specific carburetor or throttle body access procedures.

General Installation Steps:

1. Preparation: Disconnect the existing throttle cable from the carburetor/throttle body and the accelerator pedal.
2. Mounting the Carburetor Bracket: Secure the provided carburetor bracket to the carburetor or intake manifold according to the vehicle's configuration. Ensure it is stable and does not interfere with other engine components.
3. Cable Routing: Route the new Lokar throttle cable from the accelerator pedal area through the firewall to the carburetor/throttle body. Ensure the cable is routed away from hot or moving parts and has no sharp bends.
4. Accelerator Pedal Connection: Connect the accelerator pedal end of the cable to the pedal mechanism. Adjust for proper pedal travel and tension.
5. Carburetor/Throttle Body Connection: Connect the carburetor end of the cable to the throttle lever. Install the return spring to ensure the throttle closes fully when the pedal is released.
6. Adjustment: Adjust the cable tension to eliminate slack without causing the throttle to open. Ensure full throttle opening and complete closure.
7. Testing: With the engine off, manually operate the accelerator pedal to verify smooth operation and full range of motion. Start the engine and re-verify operation at idle and with light throttle input.

Note: Detailed, step-by-step instructions with diagrams are typically included with the product packaging. Always refer to those specific instructions for your application.

4. Operation

The Lokar XDP-1000HT throttle cable system operates by transmitting mechanical input from the accelerator pedal to the carburetor or throttle body, controlling engine speed. Proper installation and adjustment are crucial for safe and effective operation.

• Ensure the accelerator pedal moves freely and returns to its resting position without sticking.
• Verify that the throttle opens smoothly and closes completely when the pedal is released.
• Avoid excessive force on the accelerator pedal, as this can damage the cable or linkage.

5. Maintenance

Regular inspection and maintenance will ensure the longevity and reliable performance of your Lokar throttle cable kit.

• Periodic Inspection: Annually inspect the entire cable assembly, including the housing, cable, and all connections, for signs of wear, fraying, corrosion, or damage.
• Lubrication: While Lokar cables are designed for low maintenance, a light application of a suitable cable lubricant can be applied to the inner wire at the ends if desired, to ensure smooth operation. Avoid lubricants that attract dirt.
• Cleaning: Keep the cable and its connections clean from dirt, grease, and debris. Use a mild cleaner and soft cloth.
• Hardware Check: Periodically check all mounting hardware for tightness.

6. Troubleshooting

If you experience issues with your throttle cable system, consider the following troubleshooting steps:

• Sticking Throttle: Check for kinks or sharp bends in the cable housing. Ensure the cable is not binding on any engine components. Verify the return spring is properly installed and functional. Inspect the carburetor/throttle body linkage for obstructions.
• Excessive Pedal Play: Adjust the cable tension to remove slack. Ensure all connections are secure.
• Incomplete Throttle Opening: Check for proper cable adjustment. Ensure the cable is not binding and allows full travel of the throttle lever.
• Cable Fraying/Damage: If the cable shows signs of fraying or significant damage, it must be replaced immediately to prevent failure.

7. Specifications

8. Warranty Information

The Lokar XDP-1000HT Midnight Series Duo-Pak Kit is backed by a Lifetime Warranty. This warranty covers defects in materials and workmanship under normal use. For specific details regarding warranty claims and coverage, please refer to the official Lokar website or contact their customer support.

9. Support

For further assistance, technical support, or to inquire about replacement parts, please contact Lokar customer service. You can typically find contact information and additional resources on the official Lokar website.

Website: www.lokar.com (Example, please verify official website)

Always provide your product model number (XDP-1000HT) when contacting support for efficient service.