5. Slide the shifter body onto the left handle-
bar. Guide the shifter cable around the head-
light (LE or SX models) or battery holder (PE
models).
6. Slide the shim onto the handlebar. Roll the
handlebar grip onto the handlebar until the grip
is flush with the handlebar end.
7. Slide the shifter against the handlebar
grip/shim.
8. Position the shifter body as described in
Chapter Six, and tighten the shifter-body clamp
bolt to the torque specification in Table 4.
9. Slide the brake-lever body against the
shifter. Position the brake lever as described in
Chapter Five, and torque the brake-lever
clamp bolt to the specification in Table 4.
10. Fit the mirror mount into the handlebar end
(Figure 10). Position the mirror, and tighten the
mirror mounting bolt to the torque specification
in Table 4.
11.Slide the accessory control against the
brake lever. Rotate the control on the handle-
bar to the same relative position as the throttle
control housing. Tighten the clamp bolt so
there is enough friction to hold it in place. Do
not over tighten the clamp bolt.
12. Use the S-hook to secure the shifter cable
to the front brake cable (C, Figure 1).
13. Reinstall the cable inlet cover and right
side cover.
HEADSET
A 36-mm spanner (Park Tool HCW-15) is
required for servicing the headset.
Disassembly
1. Mark the stem height with tape so it can be
easily reset to the correct height during assem-
bly.
2. Break the stem-binder bolt loose (A, Figure
4).
3. Remove the front wheel.
4. Disconnect the brake cable from the front
brake lever by performing the following.
a. Loosen the adjuster locknut (A, Figure
13) at the brake lever. Turn the adjusting
barrel (B, Figure 13) and the locknut
until their slots align with the slot in the
brake lever body.
b. Pull the cable housing from the adjusting
barrel, and slide the inner cable through
the slots in the brake lever, adjusting
barrel and adjuster locknut.
c. Disconnect the inner-cable end from the
anchor (C, Figure 13) on the brake lever.
5. Loosen the handlebar binder bolts (A,
Figure 1), remove the handlebar clamp, and
remove the handlebar from the binder on the
handlebar arm.
6. Remove the stem/handlebar arm assembly
from the fork column.
7. On PE and SX models, perform the follow-
ing.
a. Note the position of the stanchion caps
(A, Figure 14) relative to the upper fork
bridge (B, Figure 14). The fork bridge
will have to be reinstalled in the same
position during assembly.
b. Loosen each stanchion clamp bolt (A,
Figure 15) and loosen the fork bridge
clamp bolt (B. Figure 15).
c. Carefully slide the upper fork bridge off
each stanchion and remove the fork
bridge. Do not lose the fork bridge collar.
8. Use a bungee cord or wire to suspend the
handlebar assembly from the frame.
9. On PE models, remove the bolt (Figure 16)
that secures the battery holder to the lower
fork bridge.
HANDLEBAR and CONTROLS
4-5
FIG. 13
FIG. 14
B
B
C
A
A