Yamaha YZF-R15, Service Manual

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HANDLEBARS HANDLEBARS
REMOVING THE HANDLEBARS
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
CHECKING THE HANDLEBARS
1. Check:
• Left handlebar
• Right handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
INSTALLING THE HANDLEBARS
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder “2”
• Front brake light switch
NOTE:
• Install the brake master cylinder holder with the
arrow mark “a” pointing forward.
• Align the mating surfaces of the brake master
cylinder holder with the punch mark “b” on the
handlebar.
• First, tighten the front bolt, then the rear bolt.
3. Install:
• Front brake light switch
NOTE:
Before fully installing the front brake light switch,
be sure to completely install the rubber cover
over the switch. Also, be sure not to twist the
front brake light switch lead when screwing in
the switch.
4. Install:
• Throttle grip “1”
• Throttle cable
• Right handlebar switch “2”
NOTE:
• Be sure to position the washer between the
throttle grip and the right handlebar switch.
• Lubricate the end of the throttle cable and the
inside of the throttle grip with a thin coat of the
lithium-soap-based grease, and then install the
throttle grip onto the right handlebar.
• Route the throttle cable through the slot in the
throttle grip, and then install the cable.
• Align the projection “a” on the right handlebar
switch with the hole“b” on the right handlebar.
T
R
.
.
Front brake master cylinder hold-
er bolt
7 Nm (0.9 m·kg, 6.5 ft·lb)
2
1
b
a
FWD
5. Install:
• Right grip end “1”
There should be 1–3 mm (0.04–0.12 in) of clear-
ance “a” between the throttle grip and the right
grip end.
6. Install:
• Clutch lever holder “1”
Align the mating surfaces of the clutch lever
holder with the punch mark “a” on the left han-
dlebar.
7. Install:
• Clutch lever
• Clutch switch “1”
Align the projection “a” on the clutch switch with
the slit “b” in the clutch lever holder.
8. Connect:
• Clutch cable
Lubricate the end of the clutch cable with a thin
coat of lithium-soap-based grease.
9. Install:
• Left handlebar switch “1”
Align the projection “a” on the left handlebar
switch with the hole “b” in the left handlebar.
10.Connect:
• Clutch switch coupler
11.Install:
• Handlebar grip “1”
• Left grip end “2”
a. Apply a thin coat of rubber adhesive onto the
end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
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