Kwikset 138 INSTL KIT User Manual

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1

A. DOOR PREPARATION

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Important: Protective eye wear recommended.

NOTE: If required, see section B for metal door drilling or
section C for drilling 1-1/2” diameter holes before beginning.

1.

(1)

Adjust backset spacers for required backset, either

2-3/8” (60mm) or 2-3/4” (70mm).

2.

(1)

Place jig on door with centerline of jig 38” (965mm) from

floor.

(2)

Tighten jig with handle until snug, then
thumb screw adjuster to take out slack for parallel alignment.
Once parallel,

(4)

tighten down adjuster nut.

(3)

tighten

3. •Tighten drill chuck onto drill adapter. •Slide

prepared drill to lock onto the 2-1/8” drill bit. •Drill
the 2-1/8” hole through door.

prefer drilling from both sides: clip the boring depth
stop onto mandrel and remove snap ring, to allow
only tip of drill to break though door. After drilling,
replace snap ring.

drill from bit by depressing adapter button.

4. •Slide prepared drill to lock onto the 1” spade

bit. •Drill the 1” hole 2-1/4” deep in door edge
(

wood edges only). •Remove drill from bit by

depressing adapter button.

•When completed, disconnect

Note, for those who

5. •Remove jig from door.

•Insert the latch mortising
tool into the 1” hole.

•Strike top of tool solidly
so that blade cuts to the
5/32” depth required.

•Chisel out area scribed.

6. Put strike locator into

1” hole, close door and
push locator into jamb to
mark center of strike hole.

7. •Where marked in door

jamb, drill a 1” diameter hole.

•Drill 5/8” (16mm) deep for
knobs levers or handlesets,
1” (25mm) deep for
deadbolts. •Insert appropriate
strike mortising tool into 1”
diameter hole in jamb. •Strike
top of tool solidly. •Chisel out
area scribed to the depth
indicated on lockset
instructions and continue with
lockset instructions for
installation.

B. METAL DOOR SET-UP. Metal door drilling requires the hole

saw assembly and the longer guide arm. To exchange guide arms:

(1)

Remove snap ring from the 2-1/8” drill bit, then
bit from jig.
from guide pin and jig.
aligning onto guide pin.
screw.
ring. Return to DOOR PREPARATION section A.

1.

(3)

Back-out flat head screw and

(5)

Place the taller guide arm onto jig

(6)

(7)

Install hole saw assembly into jig and secure with snap

BACKSET

Secure arm by tightening the flat head

SPACER

(2)

remove drill

(4)

remove guide arm

2.

38"

(9

6

5

m

m

)

(1)

(1)

SPACER

(1)

C. FOR OPTIONAL 1-1/2” (38MM) DIAMETER HOLE DRILLING.

(1)

Remove snap ring from 2-1/8” drill bit and

jig.

(3)

Insert the 1-1/2” drill bit into jig and

(5)

Place ring adapter into the 2-1/8” jig hole and
threading down the set screw. Note: If drilling a hole for model 663
deadbolt (not through door), remove drill tip from drill bit before
placing jig on door and clip boring depth stop onto mandrel of drill
bit before drilling. Return to DOOR PREPARATION section A.

(2)

remove bit from

(4)

secure with snap ring.

(6)

secure it by

3.

(2)

(4)

(3)

4.

B.

WOOD

EDGE
ONLY

(1)

SNAP RING

5.

(2)

(4)

(3)

GUIDE PIN

C.

(1)

SNAP
RING

(2)

(4)

(3)

LOCATOR

6.

TALL GUIDE ARM

(FOR METAL DOOR)

(5

GUIDE PIN

JAMB

RING ADAPTER

(5

(6

(6

7.

MANDREL

BORING
DEPTH
STOP

(7)

JAMB

Copyright © 2000 Kwikset Corporation

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