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Frame and suspension
6 . 3
5.3 Loosen bar end weight centre screw
5.5 Disconnect the brake light switch
5.7 On Speedfight models, detach the turn
(A) to release nut (6)
wiring connectors
signal relay from the handlebars
5 Handlebars
-
removal and installation
Removal
1 Remove the handlebar covers where
applicable. On Speedfight and Vivacity
models, remove the kick panel (see Chap-
ter 7).
2 If required, the handlebars can be
displaced from the steering head for access
to the bearings without having to detach any
cables, hoses or main wiring looms, or
remove the switches, brake levers or master
cylinders. If this is the case, ignore the Steps
which do not apply.
3 Where fitted, loosen the centre screws for
the bar end weights and withdraw the weights
from the handlebars. Take care not to undo
the screws too far and lose the nuts on the
end of the screws (see illustration).
4 Undo the throttle twistgrip housing screws
and slide the twistgrip off the end of the
handlebar (see Chapter 4).
5 Disconnect the wiring from each brake light
switch (see illustration).
6 Undo the handlebar switch housing screws
and displace the housing (see Chapter 9).
7 On Speedfight models, detach the turn
signal relay from the bracket on the
handlebars (see illustration).
8 Unscrew the
brake master cylinder
assembly clamp bolts and position the
assembly clear of the handlebar, making sure
no strain is placed on the hydraulic hose (see
Chapter
8 ) .
Keep the master cylinder reservoir
upright to prevent air entering the system.
Note:
Some models are
fitted
with
hydraulically operated front and rear brakes,
on others only the front brake is hydraulically
operated.
9 Remove the left-hand grip; peel the grip off
the end of the bar, or if necessary cut it off.
10 On Speedfight 2 Furious and Metal-X
Furious models, use a Torx wrench to
unscrew the bolts securing the handlebar
clamps (see illustration). Support the
handlebars and lift the clamps off, then
remove the handlebars. On all other models,
unscrew the nut on the handlebar stem bolt
and remove the nut, washer and shaped
spacer, noting how they fit (see illustration).
11 Support the handlebars and withdraw the
bolt, then lift the bars off the steering stem. If
the handlebar components have been left
attached, position the bars so that no strain is
placed on any of the cables, hoses or wiring,
and protect the bodywork to prevent
scratching.
Installation
12 Installation is the reverse of removal,
noting the following.
Refer to the Specifications at the beginning
of this Chapter and tighten the handlebar
stem bolt to the specified torque setting.
Use a suitable adhesive between the left-
hand grip and the handlebar.
Don't forget to reconnect the brake light
switch wiring connectors.
Check the operation of the brakes before
riding the machine.
5.10a Handlebar clamps are secured by four bolts
5.10b Remove the nut (A), washer (6) and spacer (C)
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