Buell 2004 XB9S, Service Manual

Page: 173 / 597

2-70 2004 Buell Lightning: Chassis
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HANDLEBARS 2.27
REMOVAL
1. Remove seat. See 2.41 SEAT .
1 1
WARNING
1
WARNING
To avoid accidental start-up of vehicle and possible per-
sonal injury, disconnect the negative battery cable
before proceeding. Inadequate safety precautions could
result in death or serious injury.
2. Disconnect battery negative cable.
3. Remove left handlebar switch housing. See 7.17 HAN-
DLEBAR SWITCHES . Cut left handlebar grip and
remove.
4. Detach clutch hand control from handlebars. See 2.24
CLUTCH HAND LEVER .
5. Remove front brake master cylinder. See 2.10 FRONT
BRAKE MASTER CYLINDER AND HAND LEVER .
6. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.23 THROTTLE CONTROL .
7. See Figure 2-100. Remove the four screws holding
upper handlebar clamp.
NOTE
Right hand control assembly may now be removed from
detached handlebar.
8. Remove handlebars without stretching throttle cables.
9. See Figure 2-100. Remove endcaps.
INSTALLATION
1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing to handlebar. See
2.23
THROTTLE CONTROL .
2. See Figure 2-100. Attach handlebars.
a. Position handlebar on lower clamp.
b. Place the upper handlebar clamp in position and
thread the four screws in place after applying Loctite
272 (Red).
c. Tighten both front screws to 10-12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws (2) 10-12 ft-lbs (14-16
Nm).
3. Install clutch hand control. See 2.24 CLUTCH HAND
LEVER .
4. Install left switch housing. See 7.17 HANDLEBAR
SWITCHES .
5. Check control wire routings. See HOSE AND WIRE
ROUTING.
a. Route right hand control wires between the lower
clamp and fork tube and on the outside of the clutch
cable.
b. Route left hand control wires between the lower
clamp and fork tube.
6. Install a new left hand grip.
7. Install front brake master cylinder. See 2.10 FRONT
BRAKE MASTER CYLINDER AND HAND LEVER.
8. Check steering motion range to both fork stops.
1 1
WARNING
1
WARNING
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
9. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See
1.5 BATTERY MAINTENANCE .
1 1
WARNING
1
WARNING
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
10. Install seat. See 2.41 SEAT .