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 NВ·m (1.0 kgfВ·m, 87 inВ·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 NВ·m (8.0 kgfВ·m, 58 ftВ·lb) Front Fork Clamp Bolts (Upper): 20 NВ·m (2.0 kgfВ·m, 15 ftВ·lb) Handlebar Clamp Bolts: 25 NВ·m (2.5 kgfВ·m, 18 ftВ·lb)

NOTE

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

If the handlebar does not turn to the steering stop it may cause an accident resulting in injury or death.

Be sure the cables, harnesses and hoses are routed properly and do not interfere with handlebar movement (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 NВ·m (0.36 kgfВ·m, 31 inВ·lb)

• Install the throttle cable tips.
• Install the throttle case.

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

• Tighten: Torque - Throttle Case Screws: 3.5 NВ·m (0.36 kgfВ·m, 31 inВ·lb)

• 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)