Place motorcycle on its centre stand.
Remove seat.
Remove left, right and centre covers.
Cut the cable tie at the handlebar.
Caution! Refer to notes on the hazards involved in handling brake fluid.
Disconnect and seal brake hose (1).
Remove brake microswitch (2).
Release cover (6) and leave it dangling on the cable.
Remove throttle-cable roller (7) and disengage throttle-cable nipple (8).
Remove brake fitting.
Remove fastener for throttle cable (arrow) and pull out the throttle cable.
Remove handlebar weight (4).
Remove housing (3) together with twist-grip tube (5).
Disconnect the expansion tank and pull it to one side.
Remove the fasteners securing the oil tank and allow the oil tank to dangle to one side on the hoses.
Remove the starter relay from the holder.
Remove the lid of the electronic equipment box.
Cut through the cable tie holding the wiring harness at the electronic equipment box.
Disengage cover from the anchorage on main frame on left.
Disconnect plug of right-hand multi-function switch (1).
Push the cover over the cylinder head slightly to one side and remove the connector.
Cut through the cable ties securing the cables at the multi-function switch and the clutch switch.
Installation is the reverse of the removal procedure: pay particular attention to the following.
Caution! Top up brake fluid and bleed brake system.
Note: Before assembling, grease the handlebar end and nipple mount (arrow) lightly with Shell Retinax EP2.
Position the twist-grip tube in the groove before mounting it on the handlebar.
Note: The position of the handlebar fittings is indicated by a punch mark (arrow) on the handlebar.
Throttle cable play: approx. 1 mm (0.04 in).
Tightening torques:
- Handlebar fitting to handlebar: 9 Nm
- Handlebar weight to handlebar: 9 Nm
- Brake hose to brake master cylinder: 18 Nm
- Oil tank to intake air silencer: 9 Nm
- Lid of electronic equipment box: 4 Nm
- Expansion tank to radiator: 9 Nm