provide maximum slack in the cable and disconnect
the cable end from the clutch hand lever.
8. Disconnect the electrical lead (C,
Figure 40
)
from the clutch switch.
9. Remove the clutch lever nuts and bolts (D,
Fig-
ure 40
), and remove the clutch lever assembly.
10. Remove the caps (A,
Figure 41
), then loosen
the clamp bolts (B) on the upper handlebar holders.
11. Remove the upper handlebar holders from the
handlebar and lift the handlebar from the lower han-
dlebar holders.
12. If necessary, replace the left hand grip as fol-
lows:
a. Unscrew the handlebar end and remove it
from the handlebar.
b. Insert a thin-bladed screwdriver under the
hand grip.
c. Squirt electrical contact cleaner under the
hand grip and twist it quickly to break its seal
and remove it.
d. Apply a thin layer of rubber cement to the end
of the handlebar when installing a new grip.
e. Check the hand grip after 10 minutes to make
sure it is tight.
WARNING
Do not ride the motorcycle with a
loose hand grip. Loss of control will
occur.
13. Installation is the reverse of removal. Note the
following:
a. Replace the handlebar if it is bent.
b. Make sure the punch mark on the handlebar
(A,
Figure 42
) aligns with the top edge of the
lower handlebar holder.
c. Install the upper handlebar holders so the
punch mark on the top of each holder (B,
Fig-
ure 42
) faces forward.
d. Tighten the handlebar holder clamp bolts to
28 N•m (21 ft.-lb.). Tighten the front bolt
first, then tighten the rear bolt for each han-
dlebar holder.
e. Position the clutch lever bracket (A,
Fig-
ure 43
) so the gap in the bracket clamp
aligns with the index mark (B) on the han-
dlebar.
f. Install the left handlebar switch and the right
handlebar switch as described in Chapter
Nine.
g. Lubricate the ends of the clutch and throttle
cables with lithium soap grease.
h. Lubricate the throttle grip assembly with lith-
ium soap grease.
i. Install the front brake master cylinder as
follows:
j. Position the master cylinder so the face of the
clamp mating surface aligns with the mark on
the handlebar. See A,
Figure 44
.
k. Install the master cylinder clamp (B,
Figure
44
) so the UP stamped on the clamp faces up.
322
CHAPTER ELEVEN
40
41
42
