14-12 STEERING

Handlebar

Handlebar Removal

•Remove:

Steering Damper (see Steering Damper Removal) Clutch Lever Clamp Bolts [A]

Clutch Lever Assembly [B] Left Switch Housing [C] Handlebar Weight [D]

Left Handlebar Grip [E]

•Remove:

Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter)

Right Switch Housing [B] Throttle Case [C] Handlebar Weight [D] Throttle Grip [E]

•Loosen:

Upper Front Fork Clamp Bolt [A] (Both Sides) Handlebar Clamp Bolt [B] (Both Sides)

•Remove:

Steering Stem Head Nut [A] and Washer Steering Stem Head [B] with Handlebars

•Remove:

Handlebar Positioning Bolts [A] Handlebars

STEERING 14-13

Handlebar

Handlebar Installation

•Apply a non-permanent locking agent to the threads of the handlebar positioning bolts and tighten them.

Torque - Handlebar Positioning Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb)

•Install the steering stem head with handlebars.

•Install the washer [A] and steering stem head nut [B].

•Tighten:

Torque - Steering Stem Head Nut: 78 N·m (8.0 kgf·m, 58 ft·lb)

Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m, 15 ft·lb)

Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

NOTE

○Tighten the steering stem head bolt before tightening the upper front fork clamp bolts and handlebar clamp bolts.

WARNING

Do not impede the handlebar turning by routing the cables, harnesses and hoses improperly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

•Apply adhesive cement to the inside of the left handlebar grip.

•Install the left handlebar grip, throttle grip and left/right handlebar weight.

•Apply a non-permanent locking agent to the threads of the handlebar weight bolts, and tighten them.

•Install the left and right switch housings.

○Fit the projection [A] into a hole [B] in the handlebar.

Torque - Switch Housing Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

•Install the throttle cable tips [A].

•Install the throttle case.

○Fit the projection [B] into a hole [C] in the handlebar.

•Tighten:

Torque - Throttle Case Screws: 3.5 N·m (0.36 kgf·m, 31 in·lb)

14-14 STEERING

Handlebar

•Install:

Clutch Lever Assembly (see Clutch Lever Installation in the Clutch chapter)

Front Master Cylinder (see Front Master Cylinder Installation in the Brakes chapter)

Steering Damper (see Steering Damper Installation)