ANUAL SERVICE M

HANDLEBAR

REMOVAL

Remove the handlebar pad from the handlebar.

Remove the wire bands.

Remove the screw and engine stop button.

Remove the bolts and clutch lever holder.

Remove the bolts and front brake master cylinder holder.

Remove the wire bands.

Remove the screws and engine starter switch hous­ing.

If you will not disassemble the throttle housing, remove the throttle housing as an assembly as fol­lows.

Loosen the throttle housing bolts, turn the handle­bar to the right fully, then remove the throttle hous­ing.

If you will disassemble the throttle housing, remove the dust cover and bolts.

Remove the throttle housing from handlebar. Disconnect the throttle cables from the throttle pipe.

Loosen the handlebar lower holder nuts.

Remove the bolts, upper holders and handlebar. Remove the nuts, washers, bushings and lower holders.

INSTALLATION

Install the bushings, lower holders, washers and handlebar holder nuts as shown (standard position).

The lower holder standard position as shown.

• By turning the lower holder 180 degrees, you can install it 6 mm (0.24 in) rearward of the standard position. By installing the optional lower holder, you can set it 3 mm (0.12 in) rearward of the standard position.

- Standard: 3 mm (0.12 in) offset to forward

- Standard 180 degrees turn: 3 mm (0.12 in) off­set to rearward

- Optional: No offset

Loosely install the handlebar and upper holders.

NUTS/WASHERS/BUSHINGS

Align the paint mark on the handlebar with the top of the lower holder.

Place the upper holder on the handlebar with the punch marks facing forward.

Install and tighten the front handlebar upper holder bolts first, then tighten the rear bolts to the specified torque.

TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft)

Tighten the handlebar lower holder nuts to the specified torque.

TORQUE: 44 N m (4.5 kgf-m, 32 lbf-ft)

If you did not disassemble the throttle housing, apply grease to the sliding surface of the throttle pipe.

Install the throttle housing, aligning the end of the housing with the paint mark on the handlebar. Tighten the throttle housing upper bolt first, then the lower bolt.

Adjust the throttle grip freeplay (page 4-9).

If you disassemble the throttle housing, install it as follows:

Apply oil to the throttle pipe sliding surface.

Apply grease to the throttle cable end and sliding area.

Connect the throttle cables to the throttle pipe. Install the throttle housing, aligning the end of the housing with the paint mark on the handlebar. Tighten the throttle housing upper bolt first, then the lower bolt.

Tighten the throttle bolt to the specified torque. TORQUE: 4 N m (0.4 kgf m, 3.0 Ibf-ft)

Install the throttle housing dust cover.

Adjust the throttle grip freeplay (page 4-9).

If the handlebar grips are removed, apply Honda Bond A or Pro Honda Handgrip Cement (U. S.A. only) to the inside of the grip and to the clean sur­faces of the throttle pipe and the left end of the han­dlebar.

Wait 3-5 minutes and install the grip.

Rotate the grips for even application of the adhe­sive.

Align the "Д" mark on the left grip with the paint mark on the handlebar.

Align the mark on the right grip with the edge of the throttle grip end.

Align the engine start switch housing as shown. Install and tighten the screws to the specified torque.

TORQUE: 1.15 N-m (0.1 kgf m, 0.8 Ibf-ft)

Install the wire bands.

Position the brake master cylinder on the handlebar.

Install the master cylinder holder with its "UP" mark facing up and align the end of the holder with the paint mark on the handlebar.

Tighten the upper master cylinder holder bolt first, then tighten the lower bolt.

TORQUE: 9.9 N-m (1.0 kgf-m, 7.3 Ibf ft)

Install the clutch lever bracket and holder with the punch mark on the holder facing up.

Align the end of the holder with the paint mark on the handlebar.

Tighten the upper bolt first, then the lower bolt securely.

Install the engine stop button on the handlebar. Align the end of the holder with the paint mark on the handlebar.

Install the engine stop button screw with the washer and engine stop button wire terminal.

Tighten the engine stop button screw to the speci­fied torque.

TORQUE: 1.5 N m (0.2 kgf-m, 1.1 Ibf ft)

Route the wire Clamp the engine stop button/clutch switch wire

properly ('05 - '07: with wire bands. page 1-25, After '07: page 1-32).

Install the handlebar pad.

-NT4 iv

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