Removing The Handlebar; Checking The Handlebar; Installing The Handlebar - Yamaha 2009 XP500Y TMAX Service Manual

EAS4B51014

REMOVING THE HANDLEBAR

1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Remove:
• Handlebar grip "1"
TIP
Blow compressed air between the left end of the
handlebar and the handlebar grip, and gradually
push the grip off the handlebar.
EAS22880

CHECKING THE HANDLEBAR

1. Check:
• Handlebar
Bends/cracks/damage → Replace.
EWA13690
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS22931

INSTALLING THE HANDLEBAR

1. Stand the vehicle on a level surface.
EWA13120
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
• Handlebar
Handlebar nut
40 Nm (4.0 m·kg, 29 ft·lb)
TIP
Route the right handlebar switch lead "1", left
handlebar switch lead "2", and rear brake hose
"3" through the opening "a" in the handlebar. Re-
fer to "CABLE ROUTING" on page 2-35.
1
3. Install:
• Lower handlebar cover
TIP
Route the throttle cables "1" and rear brake lock
cable "2" through the lower handlebar cover.
2
4. Install:
• Handlebar grip
M MMM M MMM M M MMM M
a. Apply a thin coat of a rubber adhesive to the
left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
EWA13700
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
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5. Install:
• Rear brake master cylinder assembly "1"
• Rear brake master cylinder holder "2"
Brake master cylinder holder bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
TIP
• Install the rear brake master cylinder holder
with the "UP" mark "a" facing up.
• Align the end of the brake master cylinder hold-
er with the punch mark "b" on the handlebar.
• First, tighten the upper bolt, then the lower bolt.
4-46
HANDLEBAR
a
2
3
1
M MMM M M MMM M M MMM M
L LLL L L LLL L L LLL L
MMM
LLL