Removal
Warning! To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding.
1. Remove main fuse.
Notice: Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch.
Note. Place a 5/32 in (4 mm) thick cardboard insert between the brake lever and lever bracket. Without the insert, the rubber boot and plunger of the front stop lamp switch can be damaged.
2. See Figure 6-138. Place the cardboard insert between the brake lever and lever bracket.
Figure 6-138. Install cardboard insert
3. Using a T27 TORX drive head, remove the two screws with flat washers securing the handlebar clamp to the master cylinder housing. Remove the brake lever/master cylinder assembly and clamp from the handlebar.
4. Using a T25 TORX drive head, remove the upper and lower switch housing screws.
5. Remove the friction shoe from the end of the tension adjuster screw.
Note. The friction screw is a loose fit. It may fall out or become dislodged if the lower switch housing is turned upside down or shaken.
6. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings.
7. Remove the throttle control grip from the end of the handlebar.
8. Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Place a drop of light oil on the retaining rings, if necessary. Remove the cables from the switch housing.
Disassembly
Notice: Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch.
1. Place the cardboard insert between the brake lever and lever bracket.
2. Remove the upper and lower switch housing screws.
3. If replacing lower housing switches, perform steps 4 through 7 before continuing to repair section. If replacing upper housing switches, proceed directly to repair section.
4. See Figure 6-147. Loosen the upper screw (1) securing the handlebar switch clamp to the master cylinder housing. Remove the lower clamp screw with flat washer (2).
Figure 6-147. Handlebar switch clamp screws: 1. Upper screw; 2. Lower screw and flat washer
5. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings.
6. Remove the friction shoe from the end of the tension adjuster screw.
Note. The friction shoe is a loose fit. It may fall out or become dislodged if the lower switch housing is turned upside down or shaken.
7. Remove the throttle control grip from the end of the handlebar.
Switch repair/replacement
Switch and lead replacement
After cutting off the connector terminals, pull the leads of faulty switches through the conduit. Route replacement switch leads through the conduit. Terminate the leads at the connector. If necessary, replace the switches.
Switch only replacement: upper housing
Note. If only one switch is faulty, replace the horn switch and high/low beam switch as a single assembly.
1. See Figure 6-139. From inside the switch housing, remove the screw with lockwasher (4) to release the bracket (5). Remove the bracket and switch assembly from the housing.
Figure 6-139. Upper housing without splices: 1. Start switch; 2. Stop switch; 3. Conduit; 4. Screw with lockwasher; 5. Bracket
2. Move cable conduit (3) from beneath wing of bracket. Cut wires 0.25 in (6.4 mm) from old switches (1, 2). Discard old switch and bracket assembly.
3. Slide conduit forward over cut ends of switch wires and cut off 0.5 in (12.7 mm) of conduit (3) material. Push conduit back to access switch wires.
4. See Figure 6-140. Separate new engine stop switch (2) and engine start switch (1) wires into two bundles.
Figure 6-140. Upper housing with splices: 1. Start switch; 2. Stop switch; 3. Conduit; 4. Splices; 5. Cable strap
5. See 6.33 HANDLEBAR SWITCH ASSEMBLIES for information on splicing and general repair practices.
6. See Figure 6-140. Loop switch wires and bundle splices.
7. See Figure 6-139. Route wires downstream of splices beneath wing on engine stop switch side of bracket.
8. See Figure 6-140. Install a new 7.0 in (177.8 mm) cable strap (5) beneath wing on engine start switch side (1) of bracket and capture wire splices (4).
9. Place switch assembly into upper housing aligning hole in bracket with threaded hole in boss. Seat the bracket. The step at the edge of the boss captures the bottom edge of the bracket. Tabs on each side of the bracket fit in slots cast into the housing.
10. See Figure 6-139. Install screw and lockwasher (4) to secure bracket (5) inside housing. Verify that wing on engine stop switch (2) side of bracket captures edge of conduit (3) as shown.
11. Securely tighten cable strap to draw splices to bracket. Trim cable straps.
Switch only replacement: lower housing
1. From inside the switch housing, carefully cut cable strap to free conduit from the turn signal switch bracket.
2. Remove the screw with lockwasher to release the turn signal switch bracket. Remove the bracket and switch assembly from the housing.
Turn-right signal switch only
1. Cut wire 1.5 in (38.1 mm) from old switch. Discard old switch assembly.
2. See 6.33 HANDLEBAR SWITCH ASSEMBLIES for information on splicing and general repair practices.
Front stop lamp switch only
1. Carefully remove the wedge between the switch and switch housing, if present. To remove the switch from the housing, press the plunger and slowly rotate switch upward while rocking slightly.
2. Cut wires 1.0 in (25.4 mm) from old switch. Discard old switch.
3. See 6.33 HANDLEBAR SWITCH ASSEMBLIES for information on splicing and general repair practices.
4. Carefully press plunger against inside wall of switch housing. With thumb over plunger bore, move switch into the installed position in the switch housing cavity. When plunger is positioned against thumb, slowly rotate switch downward while rocking slightly. Release the plunger only after switch is properly positioned in the cavity.
5. Verify that the plunger is square in the bore and that the boot is not compressed, collapsed or torn. If necessary, gently work the plunger in and out until boot is fully extended.
6. See Figure 6-141. Push down on switch (1) so that it bottoms against housing and wires (3) run in groove at base of cavity. With the concave side facing outward, insert wedge (2) between switch and outboard side of switch housing.
Figure 6-141. Install stop lamp switch: 1. Stop lamp switch; 2. Wedge; 3. Switch wires; 4. Lower switch housing
7. Push wedge down until it also bottoms against housing. Verify that the plunger is still square in the bore. Place a drop of RTV SILICONE SEALANT on upper corner of wedge.
Assembly
1. See Figure 6-142. Insert tapered end of new 7.0 in (177.8 mm) cable strap (1) into round hole in turn signal switch bracket (2) and then feed back through using the adjacent hole. Reserve the oblong hole for the bracket screw.
Figure 6-142. Insert cable strap in switch bracket: 1. Cable strap; 2. Bracket; 3. Right turn signal switch
Note. Be sure that all splices are positioned above the turn signal switch bracket.
2. Place the turn signal switch assembly into the housing, aligning the oblong hole in the bracket with the threaded hole in the boss. Be sure that the bracket is fully seated. Tabs on each side of bracket are captured in slots cast into switch housing.
3. Start screw with lockwasher to secure bracket inside housing.
Notice: If routed incorrectly, wires can be pinched by casting or handlebar resulting in switch failure.
4. Loop switch wires so that spliced lengths are positioned across bracket.
5. Capturing conduit about 0.25 in (6.4 mm) from end, securely tighten cable strap to draw conduit to bracket. Trim cable straps.
6. Install second 7.0 in (177.8 mm) cable strap capturing conduit and wire splices. Securely tighten cable strap to draw splices to conduit. Trim cable straps.
7. Tighten screw to secure bracket inside housing.
8. Route wire bundle to upper switch housing by gently pressing conduit into channel next to angular arm of bracket.
9. Secure bundle to arm using third cable strap. Trim cable straps.
10. If necessary, bend angular arm of bracket downward to firmly secure front stop lamp switch in position.
Installation
| FASTENER | TORQUE VALUE | |
| Handlebar control lever clamp screw | 108-132 in·lbs | 12.2-14.9 Nm |
| Switch housing screw | 35-45 in·lbs | 4.0-5.1 Nm |
1. See Figure 6-143. Push the throttle and idle control cables into the lower switch housing until they snap in place. Note the different diameter inserts crimped into the end of the throttle and idle cable housings.
Figure 6-143. Right lower module housing: 1. Idle cable insert (gold insert, rear hole); 2. Throttle cable insert (silver insert, front hole); 3. Tension adjuster screw
- a. Push the silver insert (2) of throttle cable housing into the hole in front of tension adjuster screw (3).
- b. Push the gold insert (1) of idle cable housing into the hole at the rear of tension adjuster screw (3).
Note. To aid assembly place a drop of light oil on the retaining rings of the crimped inserts. Always replace the retaining rings if damaged or distorted.
2. See Figure 6-144. Route the cable (2) to the upper switch housing as shown.
Figure 6-144. Route cable to upper switch housing: 1. End fittings; 2. Upper switch housing cable
3. Slide the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip so that the ferrule notches are at the top. To prevent binding, pull the grip back about 1/8 in (3.2 mm).
4. With the concave side facing upward, install the friction shoe so that the pin hole is over the point of the adjuster screw.
Note. The friction shoe is a loose fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken.
5. See Figure 6-145. Position lower switch housing beneath the throttle control grip. Install the brass ferrules (4) onto the cable so that the end fittings seat in the ferrule recess. Seat the ferrules in their respective notches (3) on the throttle control grip. Verify that the cables are captured in the grooves (2) molded into the grip.
Figure 6-145. Throttle cable attachment: 1. Throttle cable (silver insert, front hole); 2. Groove in throttle grip; 3. Notch; 4. Brass ferrule; 5. Idle cable (gold insert, rear hole)
6. Position the upper switch housing over the handlebar and lower switch housing.
7. Verify that the wire harness conduit runs in the depression at the bottom of the handlebar. Be sure that the upper switch housing harness will not be pinched under the handlebar when the switch housing screws are tightened.
8. Start the upper and lower switch housing screws, but do not tighten.
Notice: Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch.
9. See Figure 6-146. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab (2) on the lower switch housing in the groove (3) at the top of the brake lever bracket.
Figure 6-146. Switch housing alignment (typical): 1. Switch housing assembly; 2. Tab; 3. Groove; 4. Brake lever bracket
10. Align the holes in the handlebar switch clamp with the master cylinder housing. Start the two screws (with flat washers). Position for rider comfort. Beginning with the top screw, tighten to specification using a T27 TORX drive head. Refer to Table 6-9.
11. Using a T25 TORX drive head, tighten lower and upper switch housing screws to specification. Refer to Table 6-9.
Note. Always tighten the lower switch housing screw first so that any gap between the upper and lower housings is at the front of the switch.
Table 6-9. Handlebar switch assembly fasteners
| FASTENER | TORQUE |
| Handlebar clamp screw | 108-132 in·lbs (12.2-14.9 Nm) |
| Switch housing screws | 35-45 in·lbs (4.0-5.1 Nm) |
12. Remove the cardboard insert between the brake lever and lever bracket.
13. Adjust throttle cables. See 2.28 THROTTLE CABLES: ALL MODELS
14. Install main fuse.
Warning! Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury.
15. Test the switches for proper operation.
16. Secure wire harness to handlebar as necessary.