HANDLEBAR
Remove the handlebar pad from the handlebar.
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HANDLEBAR PAD
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ENGINE STOP BUTTON BOLTS WIRE |
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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.
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MASTER CYLINDER
HOLDER BOLTS |
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Do not disconnect the hydraulic line. Keep the brake master cylinder upright to prevent air from entering the hydraulic system. |
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STARTER SWITCH HOUSING |
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WIRE BANDS |
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Remove the wire bands.
Remove the screws and engine starter switch housing.
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'05 - '06 shown: THROTTLE HOUSING
BOLTS |
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.
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'05 - '06 shown: DUST COVER THROTTLE HOUSING
BOLTS |
Remove the throttle housing from handlebar. Disconnect the throttle cables from the throttle pipe.
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THROTTLE PIPE |
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, THROTTLE CABLES |
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FORWARD |
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LOWER HOLDER |
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LOWER HOLDERS |
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Loosen the handlebar lower holder nuts.
Remove the bolts, upper holders and handlebar. Remove the nuts, washers, bushings and lower holders.
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.
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180 DEGREES TURN STANDARD HOLDER |
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OPTIONAL LOWER HOLDER POSITION |
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STANDARD HOLDER POSITION |
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- 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.
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LOWER HOLDERS| |
NUTS/WASHERS/BUSHINGS
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HANDLEBAR |
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PAINT MARK |
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.
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PUNCH MARKS
BOLTS |
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:
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THROTTLE BOLT |
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THROTTLE CABLES |
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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).
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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.
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Allow the adhesive to dry for approximately 1 hour before using. |
Wait 3-5 minutes and install the grip.
Rotate the grips for even application of the adhesive.
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INDEX LINE |
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PAINT MARK |
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”Д" MARK |
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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.
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WIRE BANDS |
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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.
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PAINT MARK |
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"UP" MARK |
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BOLTS |
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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)
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ENGINE STOP BUTTON PAINT MARK |
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CLUTCH LEVER BRACKET/HOLDER PAINT MARK |
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.
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SCREW/WASHER |
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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)
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WIRE BANDS
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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).
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HANDLEBAR PAD |
Install the handlebar pad.
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