Buell 2002 S3T, Service Manual

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2002 Buell S3T: Chassis 2-55
HANDLEBARS 2.26
REMOVAL
1. Remove front brake master cylinder. See 2.10 FRONT
BRAKE MASTER CYLINDER .
2. Remove left handlebar switch housing. See 7.5 HAN-
DLEBAR SWITCHES . Cut left handlebar grip and
remove.
3. Detach clutch hand control from handlebars. See 2.25
CLUTCH CONTROL .
4. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.24 THROTTLE CONTROL.
5. See Figure 2-86. Remove four screws (1, 2) from handle-
bar clamp (3).
6. Slide handlebars out of throttle grip assembly to remove.
INSTALLATION
1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing to handlebar. See
2.26 HAN-
DLEBARS .
2. Install clutch hand control. See 2.25 CLUTCH CON-
TROL .
3. See Figure 2-87. Install handlebar clamp.
a. Route right hand control wires (1) under handlebar
and in front of fork tube (4) and handlebar clamp (3).
b. Route left hand control wires (2) under handlebar
and in front of fork tube (4) and handlebar clamp (3).
c. See Figure 2-86. Tighten both front screws (1) to 10-
12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws (2) 10-12 ft-lbs (14-
16 Nm).
4. Install left switch housing. See 7.5 HANDLEBAR
SWITCHES
5. Install a new left handgrip.
a. Clean end of handlebar with M600.
b. Place LOCTITE 411 ADHESIVE around inside of
grip.
c. Push grip onto handlebar end. Twist grip on bar until
end touches left switchgear housing.
d. Wipe off excess adhesive with a rag.
6. Install front brake master cylinder. See 2.10 FRONT
BRAKE MASTER CYLINDER .
7. Check steering motion range to both fork stops. See 1.16
STEERING HEAD BEARINGS .
Figure 2-86. Handlebar Clamp
Figure 2-87. Routing Hand Control Wires
6286
1. Front Clamp Screws (2)
2. Rear Clamp Screws (2)
3. Handlebar Clamp
2
1
3
6287
1. Right Hand Control Cables
2. Left Hand Control Cables
3. Handlebar Clamp on Upper Triple Clamp
4. Fork Tube
5. Front Brake Line
6. Throttle Cables
2
1
3
4
5
6