Buell P3, Service Manual

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2-72 2007 Buell P3: Chassis
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HANDLEBARS 2.30
REMOVAL
1. See Figure 2-119. Remove left side switch housing (13).
2. Loosen clutch adjuster and remove clutch cable (8).
3. Unplug clutch lever switch (9).
4. Remove left handlebar grip (12).
5. Loosen clutch lever screw (4) and slide clutch lever and
bracket assembly off of handlebar (3).
6. Disconnect front brake lever switch (16).
7. Slide rubber boot off the throttle cable adjusters. Loosen
cable adjuster lock on each adjuster.
8. Turn adjusters in direction which will shorten cable hous-
ings to minimum length providing freeplay in both cables.
9. Remove two screws on right switch assembly. Separate
housings (14) from handlebar.
10. Remove cables from notches in housings.
11. Unhook ferrules from cable wheel.
12. Remove throttle grip (15).
13. Remove front master cylinder clamp bolts.
14. Remove master cylinder.
15. Remove upper handlebar clamp screws (1) and upper
handlebar clamps (2).
16. Remove handlebar (3).
INSTALLATION
1. Position handlebar (3) on upper triple clamp.
2. Install upper handlebar clamps (2) and screws (1).
3. Tighten screws in steps maintaining even gap between
upper triple clamp and upper handlebar clamps. Final
tighten to 120-144 in-lbs (14-16 Nm).
4. Install master cylinder. Tighten master cylinder clamp
bolts to 80-120 in-lbs. (9-14 Nm).
5. Install throttle grip.
6. Hook ferules to cable wheel. Position cables in notches
of switch housing (14).
7. Position housings on right handlebar. Front housing has
locating pin that must align with hole in handlebar. Install
fasteners, longer screw on bottom. Tighten fasteners to
25-33 in-lbs (3-4 Nm).
8. Plug in front brake lever switch (16).
9. Adjust throttle cables. See 1.18 THROTTLE CABLES .
10. Install clutch lever and bracket assembly. Tighten clutch
lever screw (4) to 40-48 in-lbs (4.6-5.4 Nm).
11. Install hand grip (12).
12. Install clutch cable (8).
13. Adjust clutch. See 1.9 CLUTCH.
14. Plug terminal into clutch lever switch (9).
15. Install left side switch housing (13). Front housing has
locating pin that must align with hole in handlebar.
Tighten fasteners to 25-33 in-lbs (3-4 Nm).
Figure 2-119. Handlebar Assembly
1
14
13
3
2
16
4
6
12
9
11
10
8
a0133x2x
5
7
1. Upper handlebar clamp screw
2. Upper handlebar clamp
3. Handlebars
4. Clutch lever screw
5. Clutch lever bolt
6. Clutch lever and bracket assembly
7. Nut
8. Clutch cable
9. Switch, clutch lever
10. O-ring
11. Clamp
12. Left handlebar grip
13. Left switch assembly
14. Right switch assembly
15. Throttle grip
16. Brake lever switch
15