3.38 Handlebar

HANDLEBAR                                                                                                               3.38

PREPARE                                                       3.   Remove handlebar (1).

Replace Handlebar
                                                              INSTALL
1.   Remove  deflectors. See          HANDLEBAR      WIND            FASTENER                          TORQUE VALUE
     DEFLECTORS (Page 3-96).                                  Handlebar clamp screws                         I
                                                                                                  18-20 ft-lbs   24-27 N·m

2.   Remove wire retainers. See LEFT HAND CONTROL
                                                              Handlebar riser screws                         I
                                                                                                  35--39 ft-lbs 48-53.5 N·m

     MODULE (LHCM) (Page 8-19) and RIGHT HAND
                                                              Install Handlebar After Service
     CONTROL MODULE (RHCM) (Page 8-22).
                                                              1.   See Figure 3-124. Install handlebar assembly (1 ).
3.   Remove LHCM. See LEFT HAND CONTROL MODULE
     (LHCM) (Page 8-19).                                      2.   Install screws (2). Tighten.
                                                                   Torque: 35--39 ft-lbs (48-53.5 N·m) Handlebar riser screws
4.   Remove RHCM. See RIGHT HAND CONTROL MODULE
     (RHCM) (Page 8-22).
                                                              Install New Handlebar
5.   Detach front brake master cylinder assembly and remove   1.   See Figure 3-125. Install handlebar (1) centered on risers
     front brake line retainer from riser. See FRONT BRAKE         (4).
     MASTER CYLINDER (Page 3-29).
                                                              2.                     NOTE
6.   Detach clutch hand control assembly. See CLUTCH          Handlebar clamps have pads on one half of the top clamp.
     CONTROL (Page 3-82).                                     Clamp pads should be installed toward front of vehicle.

7.   Remove hand grips. See HAND GRIPS (Page 3-97).                Install handlebar clamps (3).

Remove Handlebar For Service                                  3.   Install screws (2). Tighten front screws then rear screws.
                                                                   Torque: 18-20 ft-lbs (24-27 N ·m) Handlebar clamp screws
1.   Remove fairing. See FAIRING (Page 3-89).

2.   Remove  deflectors. See          HANDLEBAR      WIND
     DEFLECTORS (Page 3-96).

3.   Remove rear cover from LHCM and disconnect wiring and
     clutch switch connector. See FRONT ELECTRICAL
     CADDY (Page 8-58).

4.   Remove rear cover from RHCM and disconnect wiring and
     brake switch connector. See FRONT ELECTRICAL
     CADDY (Page 8-58).

5.   Detach clutch lever assembly. See CLUTCH CONTROL
     (Page 3-82).

6.   Detach front brake master cylinder assembly. See FRONT
     BRAKE MASTER CYLINDER (Page 3-29).

REMOVE

Remove Handlebar For Service
1.   See Figure 3-124. Remove screws (2).                          1.   Handlebar assembly
                                                                   2.   Screw (2)
2.   Remove handlebar assembly (1).                                        Figure 3-124. Handlebar Assembly

Remove Handlebar
1.   See Figure 3-125. Remove screws (2).

2.   Remove handlebar clamps (3).

94000784                                                                                                                 3-99
                                                              4.   Connect LHCM wiring, clutch switch connector and rear
                                                                   cover. See FRONT ELECTRICAL CADDY (Page 8-58).

                                                              5.   Install deflectors. See HANDLEBAR WIND DEFLECTORS
                                                                   (Page 3-96).

                                                              6.   Install fairing. See FAIRING (Page 3-89).

                                                              Replace Handlebar
                                                              1.   Install LHCM. See LEFT HAND CONTROL MODULE
                                                                   (LHCM) (Page 8-19).
     1.   Handlebar
     2.   Screw (4)
                                                              2.   Install RHCM. See RIGHT HAND CONTROL MODULE
     3.   Handlebar clamp (2)
     4.   Riser (2)                                                (RHCM) (Page 8-22).
     5.   Clamp pad
                                                              3.   Install hand grips. See HAND GRIPS (Page 3-97).
                 Figure 3-125. Handlebar
COMPLETE                                                      4.   Attach clutch hand control assembly. See CLUTCH
                                                                   CONTROL (Page 3-82).
Install Handlebar After Service
                                                              5.   Attach front brake master cylinder assembly. See FRONT
1.   Attach front brake master cylinder assembly. See FRONT        BRAKE MASTER CYLINDER (Page 3-29).
     BRAKE MASTER CYLINDER (Page 3-29).
                                                              6.   Install wire retainers. See RIGHT HAND CONTROL
2.   Attach clutch lever assembly. See CLUTCH CONTROL              MODULE (RHCM) (Page 8-22) and LEFT HAND
     (Page 3-82).                                                  CONTROL MODULE (LHCM) (Page 8-19).

3.   Connect RHCM wiring, brake switch connector and rear     7.   Install deflectors. See HANDLEBAR WIND DEFLECTORS
     cover. See FRONT ELECTRICAL CADDY (Page 8-58).                (Page 3-96).

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