Kits | Suggested Tools | Skill Level(1) |
---|---|---|
55801469, 55801471, 55801473, 55801475, 55801477,55801479, 55801486, 55801491, 55801492, 55801493, 55801494, 55801499, 55801500, 55801501, 55801502 | Safety Glasses, Torque Wrench |
Verify that all contents are present in the kit before installing or removing items from vehicle. | |||||
---|---|---|---|---|---|
Item | Qty | Description | Part No. | Notes | |
1 | 1 | Handlebar | Not sold separately | ||
Items mentioned in text | |||||
A | 1 | Knurled pattern |
1. | Loosen or remove fuel tank. See service manual. |
2. | Remove inner and outer fairing assemblies. See service manual. a. Do not damage finished surfaces. | |
3. | Drain brake fluid from front brake reservoir and brake lines. See service manual. |
1. | Remove OE Handlebar. |
2. | Note front brake line routing and orientation of the banjo fittings. a. Disconnect and remove brake line. See service manual. b. Save banjo bolts and discard sealing gaskets. | |
3. | Disconnect clutch cable from clutch lever. See service manual. a. Disconnect clutch cable from side cover. b. Remove cable from vehicle. NOTE Record wire routing and cable strap locations before removal. | |
4. | Remove and discard any plastic wiring retainer clips and cable straps retaining the handlebar control and turn signal wiring from the handlebars to the harness junction connectors. a. Disconnect handlebar wiring. See service manual. NOTE
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5. | Use tape to wrap connector ends from each individual harness to make separate leaders. a. Wrap each tight enough to enter the hole. | |
6. | Remove front brake master cylinder and clutch lever assemblies from handlebar. a. Remove attached turn signal lamps and mirrors, if needed. | |
7. | Remove wire harness from handlebar. a. Set handlebar control assemblies aside. | |
8. | Remove left side switch housing assembly and wire harness. See service manual. | |
9. | Remove hand grip and set it aside for installation to new handlebar, unless being replaced. | |
10. | Remove stock handlebar from handlebar risers. See service manual. a. Save hardware and riser parts for later installation. |
1. | Stagger connectors so they are not in same locations along harness (2). a. See Figure 2. String a suitable cord (1) through handlebar. b. Tie cord to wire harness. c. Wrap tape (2) over harness. d. Tape should come to a taper (3) and be flexible to ease pulling through handlebar. e. Pull cord through bar to route wire bundle to proper exit point. | |
2. | Apply a light coat of liquid soap, window cleaner or all-purpose lubricant to right side switch wire bundle. | |
3. | See Figure 3. With handlebar placed on a smooth, soft surface, grip ends upward, gently feed right side switch wire bundle into opening on underside of new handlebar and toward the large opening in center of bar. |
4. | Pull taped ends of wire bundle through the exit opening in center of handlebar. a. Bring switch housing into approximate final position. b. DO NOT fasten switch housing to handlebar now. | |
5. | Repeat Steps 3 through 5 with left side switch wire bundle, and both turn signals, if needed. | |
6. | Remove tape from ends of wire bundles. | |
7. | Check for electrical continuity between handlebar and each wire in the wire bundles. a. Continuity would indicate a short circuit, which would require examination of wires and routing in switch housing. | |
8. | If an extension is required, install after routing wires through handlebar. |
1 | Pull cord |
2 | Taped wire harness |
3 | Tapered end |
1 | Upper switch mounting screw |
2 | Keep wires clear of pinch-points near threaded post |
3 | Wire |
4 | Hole in handlebar |
5 | Center wiring hole |
1. | See Figure 4. Install handlebar (1) to riser base. a. Route wire bundles down through upper fork bracket. | |
2. | Seat handlebar with knurled areas (A) centered on riser base. a. Install riser clamp and clamp bolts, but do not fully tighten. b. Models with Batwing Fairings: See Figure 5. Remove riser top clamp screw (1) prior to installing accessory handlbar. | |
3. | Adjust handlebar angle. a. Uprights of handlebar run roughly parallel to the front forks. NOTE Tighten front pair of riser screws first. Next tighten rear riser screws pair. | |
4. | With handlebar centered and oriented, secure riser clamp fasteners. Tighten. Torque: 21.7–24.2 N·m (16–18 ft-lbs) |
1. | Install new (purchased separately) throttle control cables and a new (purchased separately) or OE right grip/throttle sleeve assembly. See service manual. | |
2. | Adjust position of switch housing and brake lever assembly on handlebar for rider comfort. a. Handlebars without weld: See Figure 4. Install clamp against dots on handlebar, keeping clamp slot between the two dots (2) or line (1). b. Handlebars with weld: See Figure 4. Install clamp against weld, keeping clamp slot between the two dots (2) or line (1). c. Brake master cylinder must be horizontally level while vehicle is on its jiffy stand, for brake bleeding. See service manual. | |
3. | Torque brake lever clamp screws. a. First secure upper brake lever clamp screws. b. Then secure lower brake lever clamp screws. c. Tighten. Torque: 10–11 N·m (89–97 in-lbs) | |
4. | Tighten switch housing screws. Torque: 4–5.1 N·m (35–45 in-lbs) | |
5. | Verify that the right grip/throttle sleeve rotates and returns freely not binding on the handlebar or switch housing. NOTE If the handlebar grips are patterned, align the pattern on the left grip with the pattern on the right grip while the throttle is in the fully closed position. | |
6. | Install a new (purchased separately) or OE handlebar grip on left end of new handlebar according to handlebar grip instruction sheet or the service manual. | |
7. | Adjust positions of switch housing and clutch lever assembly on handlebar for rider comfort. See sevice manual. | |
8. | Torque clutch lever clamp screws. a. First secure upper clutch lever clamp screws. b. Then secure lower clutch lever clamp screws. c. Tighten. Torque: 10–11 N·m (89–97 in-lbs) | |
9. | Torque switch housing screws. a. First secure lower switch housing screws. b. Then secure upper switch housing screws. c. Tighten. Torque: 4–5.1 N·m (35–45 in-lbs) | |
10. | Install proper length clutch cable (purchased separately). See service manual. |
11. | Carefully inspect new brake lines (purchased separately) for damage or defects. Replace if damaged. | |
12. | Install brake line. See service manual or instructions included with brake lines. | |
13. | Bleed brakes. See service manual. |
1 | Riser Top Clamp Screw |
1. | Follow routing noted in disassembly steps until handlebar control wires and turn signal wires reach main vehicle harness switch and signal wire connector housings. | |
2. | Install any required electrical extension harnesses (purchased separately) for hand controls and/or front turn signal harnesses. | |
3. | Connect all harness connectors. See service manual. a. Refer to notes taken during removal. |
1. | Install fuel tank. See service manual. |
1. | Install main fuse. See service manual. |
2. | Turn ignition switch to IGNITION, but do not start vehicle. a. Test all switches and lights for proper operation. | |
3. | Turn handlebar to the left and right steering stops, testing handlebar control functions at each stop. | |
4. | Apply front brake hand lever to test operation of brake lamp. |
5. | Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual. |