Handlebars
Removal
Note: The handlebars can be displaced from the top yoke without having to remove the individual assemblies from them - follow Steps 8 and 9 only.
1. Remove the rear view mirrors (see Chapter 8).
2. Disconnect the wires from the brake light switch (see illustration). Unscrew the two front brake master cylinder assembly clamp bolts and position the assembly clear of the handlebar, making sure no strain is placed on the hydraulic hose or pipe (see illustration). Keep the master cylinder reservoir upright to prevent possible fluid leakage.
![](https://motoinstruction.ru/img/honda/19/125662.jpg)
5.2a. Disconnect the wiring connectors (arrowed)
![](https://motoinstruction.ru/img/honda/19/125663.jpg)
5.2b. Unscrew the master cylinder clamp bolts (arrowed) and displace the assembly
3. Disconnect the wires from the clutch switch (see illustration). Unscrew the two clutch lever assembly clamp bolts and position it clear of the handlebar.
![](https://motoinstruction.ru/img/honda/19/125664.jpg)
5.3. Disconnect the wiring connectors (arrowed)
4. Unscrew the handlebar switch screws and free the switches from the handlebar (see illustrations). Release the ties securing the wiring to the handlebars.
![](https://motoinstruction.ru/img/honda/19/125665.jpg)
5.4a. Right-hand switch screws (arrowed)
![](https://motoinstruction.ru/img/honda/19/125666.jpg)
5.4b ...and left-hand switch screws (arrowed)
5. Refer to Chapter 4, Section 11, and detach the throttle cables from the twistgrip.
6. Unscrew the right handlebar end-weight retaining screw, then remove the weight from the end of the handlebar and slide the throttle twistgrip off the end. If required, unscrew the left handlebar end-weight retaining screw, then remove the weight from the end of the handlebar and slide off the grip. If the grip has been glued on, you will probably have to slit it with a knife to remove it.
7. If the handlebar holders are being removed from the top yoke, slacken the nuts securing them on the underside of the yoke now.
8. If the handlebars are just being displaced and the front brake master cylinder assembly is still attached, unscrew the bolt securing the brake hose clamp to the top yoke and the bolts securing the pipe clamps to the bottom yoke - this will allow more movement in the handlebars and prevent stress on the hose and pipes (see illustration).
![](https://motoinstruction.ru/img/honda/19/125667.jpg)
5.8. Unscrew the bolt (arrowed) and displace the brake pipe holder from the top yoke
9. Unscrew the handlebar holder clamp bolts, and remove the clamps and the handlebars (see illustrations).
![](https://motoinstruction.ru/img/honda/19/125668.jpg)
5.9a. Unscrew the holder bolts (arrowed)...
![](https://motoinstruction.ru/img/honda/19/125669.jpg)
5.9b ...and remove the handlebars
10. If required, unscrew the nuts and remove the washers on the handlebar holders, then draw them out of the top yoke. Check the condition of the rubber bushes in the top yoke and replace them with new ones if they are damaged or deteriorated.
Installation
11. Installation is the reverse of removal, noting the following.
![](https://motoinstruction.ru/img/honda/19/125670.jpg)
5.11a. Align the punch mark (arrowed) with the clamp mating surfaces
![](https://motoinstruction.ru/img/honda/19/125671.jpg)
5.11b. Fit the holder with its punch mark (arrowed) at the front
![](https://motoinstruction.ru/img/honda/19/125672.jpg)
5.11c. Align the punch mark (arrowed) with the clamp mating surfaces, and fit the clamp with the UP mark facing up
- If removed, tighten the handlebar holder nuts after the handlebars are installed.
- Align the punch mark on the back of the handlebar with the mating surfaces of the left handlebar holder and clamp (see illustration). Fit the handlebar clamps with the punch mark at the front, and tighten the front clamp bolts first, then the rear, to the specified torque setting (see illustration).
- Apply some grease to the throttle twistgrip section of the handlebar.
- Make sure the front brake master cylinder assembly clamp is installed with the UP mark facing up, and with the clamp mating surfaces aligned with the punch mark on the top of the handlebar (see illustration). Tighten the master cylinder clamp bolts to the specified torque setting, tightening the top bolt first.
- Align the clutch lever assembly clamp mating surfaces with the punch mark on the back of the handlebar, and tighten the front bolt before the rear bolt.
- Make sure the pin in the lower half of each switch housing locates in its hole in the handlebar. Tighten the front housing screw first, then the rear.
- Align the throttle cable housing half mating surfaces with the punch mark on the handlebar.
- When installing the handlebar end-weights, align the boss with the groove on the inner weight inside the handlebar. Use some nonpermanent thread locking compound on the screws. If new grips are being fitted, secure them using a suitable adhesive.
- Check the throttle cable adjustment as described in Chapter 1.
- Do not forget to reconnect the front brake lightswitch and clutch switch wiring connectors.
Handlebar levers
Front brake lever
12. Unscrew the nut and remove the collar on the underside of the handguard (see illustration). Unscrew the pivot bolt and remove the handguard, then remove the lever (see illustrations).
![](https://motoinstruction.ru/img/honda/19/125673.jpg)
5.12a. Unscrew the nut and remove the collar
![](https://motoinstruction.ru/img/honda/19/125674.jpg)
5.12b. Unscrew the pivot bolt and remove the handguard...
![](https://motoinstruction.ru/img/honda/19/125675.jpg)
5.12c ...and the lever
13. Installation is the reverse of removal. Apply grease to the pivot bolt shaft and the contact areas between the lever and its bracket.
Clutch lever
14. Pull the rubber boot off the clutch cable adjuster. Slacken the adjuster lockring and thread the adjuster fully into the bracket to provide maximum freeplay In the cable (see illustration).
![](https://motoinstruction.ru/img/honda/19/125676.jpg)
5.14. Pull back the boot, then slacken the lockring and thread the adjuster in
15. Unscrew the bolt and remove the collar from the hand guard (see illustration). Counter-hold the screwhead and undo the nut on its bottom (see illustration). Remove the handguard (see illustration).
![](https://motoinstruction.ru/img/honda/19/125677.jpg)
5.15a. Unscrew the bolt and remove the collar
![](https://motoinstruction.ru/img/honda/19/125678.jpg)
5.15b. Counter-hold the screwhead and undo the nut on the bottom...
![](https://motoinstruction.ru/img/honda/19/125679.jpg)
5.15c ...and remove the handguard
16. Unscrew the pivot bolt and washer and remove the choke lever and the clutch lever, detaching the cable nipples as you do so (see illustration). Note the wave washer between the choke lever and the lever plate. Remove the plate from the lever bracket if required, noting how it fits.
![](https://motoinstruction.ru/img/honda/19/125680.jpg)
5.16. Undo the screw (arrowed), lift off the choke lever, slide out the clutch lever and detach the cable
17. Installation is the reverse of removal. Apply grease to the pivot bolt shaft and the contact areas between the lever and its bracket, and to the cable nipples. Adjust the clutch cable freeplay (see Chapter 1).