Removal
1. Remove right side cover and maxi-fuse.
2. Remove rear view mirrors and turn signals.
3. Remove throttle cables from throttle control. See 2.12 Throttle cables.
4. Remove front brake master cylinder/reservoir, turn signal assembly, and throttle control from right handlebar. See 2.17 Front brake master cylinder/reservoir.
5. Cut clip holding wiring harness to right handlebar.
6. Remove clutch master cylinder/reservoir, turn signal assembly from left handlebar. See 2.13 Clutch master cylinder/reservoir.
7. Cut clip holding wiring harness to left handlebar.
8. See Figure 2-61. To free lower end of top handlebar cover, loosen mounting bolts (3) holding headlamp bracket (2) to upper triple clamp (1).
Figure 2-61. Headlamp bracket and headlamp assembly: 1. Upper triple clamp; 2. Headlamp bracket; 3. Mounting bolt; 4. Headlamp assembly; 5. Headlamp assembly fastener and washer
9. See Figure 2-62. Without removing cover, remove fasteners (7) holding top handlebar cover (2) and instrument bezel (1) to lower handlebar cover (6).
Caution! See Figure 2-62. Snap and hook at bottom of bezel holding top cover to lower handlebar cover can be damaged if forced during removal or installation.
Figure 2-62. Handlebar assembly: 1. Instrument bezel; 2. Top handlebar cover; 3. Lower cover fasteners; 4. Upper triple clamp; 5. Bolts; 6. Lower handlebar cover; 7. Top cover fasteners; 8. Handlebar; 9. Instrument cluster; 10. Handgrip
10. From headlamp bracket end of cover, gently tilt top handlebar cover (2) and instrument bezel (1) up and back to remove cover and bezel.
Note. Bezel can remain snapped to upper handlebar cover.
Figure 2-63. Bezel hook
11. Remove wiring harness connector to instrument cluster (9) and remove instrument cluster.
12. Remove fasteners (7) holding lower handlebar cover (6) to handlebars (8).
13. If necessary, remove the handgrip (10).
14. Remove fasteners (5) holding handlebars to upper triple clamp (4). Remove handlebars.
Installation
1. See Figure 2-62. Mount handlebars (8) on upper triple clamp (4). Tighten handlebar fasteners (5) to 41-47 Nm (31-35 ft-lbs).
2. Mount lower handlebar cover (6) to handlebar (8). Tighten fasteners (3) to 6-10 Nm (53-88 in-lbs).
3. Mount instrument cluster (9). Connect wiring harness to instrument cluster.
Caution! Snap holding bottom of bezel and top cover to lower handlebar cover can be damaged if forced during removal or installation.
4. Orient instrument bezel and fit bezel hook over tab on lower handlebar cover. Gently tilt bezel (1) and top handlebar cover (2) until bezel hook snaps onto tab.
5. Fit top cover (2) under headlamp bracket. Bezel edge should fit snugly to grooved rim of lower and upper cover.
6. Install fasteners (7) that hold top handlebar cover (2), instrument bezel (1), and capture instrument cluster (9). Tighten fasteners to 1.3-1.9 Nm (12-16 in-lbs).
7. See Figure 2-61. Tighten headlamp bracket (2) fasteners (3) to 11-18 Nm (9-13 ft-lbs).
8. Install left handgrip.
9. Install left turn signal assembly, front brake master cylin-der/reservoir, and brake hand lever, and throttle control handgrip. See 2.17 Front brake master cylinder/reservoir.
10. Install a new clip to hold the wiring harness to the left handlebar.
11. Install throttle cable to throttle control handgrip. See 2.12 Throttle cables.
12. Install right turn signal assembly, clutch master cylinder/reservoir, and clutch hand lever assembly. See 2.13 Clutch master cylinder/reservoir.
13. Install a new clip to hold wiring harness to the right handlebar.
14. Install rear view mirrors and turn signals.
15. Install maxi-fuse and right side cover.