Handlebars - Buell 2003XB9S Service Manual

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HANDLEBARS

REMOVAL
1. Remove seat. See 2.41
11 1
WARNING
To avoid accidental start-up of vehicle and possible per-
sonal injury, disconnect the negative battery cable
before proceeding. Inadequate safety precautions could
result in death or serious injury.
2. Disconnect battery negative cable.
3. Remove left handlebar switch housing. See
DLEBAR SWITCHES. Cut left handlebar grip and
remove.
4. Detach clutch hand control from handlebars. See
CLUTCH HAND LEVER.
5. Remove front brake master cylinder. See
BRAKE MASTER CYLINDER AND HAND
6. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.23 THROTTLE CONTROL.
7. See Figure 2-97. Remove the four screws holding upper
handlebar clamp.
NOTE
Right hand control assembly may now be removed from
detached handlebar.
8. Remove handlebars without stretching throttle cables.
9. See Figure 2-97. Remove endcaps.
INSTALLATION
1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing to handlebar. See
THROTTLE CONTROL.
2. See Figure 2-97. Attach handlebars.
a. Position handlebar on lower clamp.
b. Place the upper handlebar clamp in position and
thread the four screws in place after applying Loctite
272 (Red).
c. Tighten both front screws to 10-12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws (2) 10-12 ft-lbs (14-16
Nm).
2-70 2003 Buell XB9S: Chassis
SEAT.
WARNING
7.16 HAN-
2.10 FRONT
LEVER.
3. Install clutch hand control. See
LEVER.
4. Install left switch housing. See
SWITCHES.
5. Check control wire routings. See
ROUTING.
a. Route right hand control wires between the lower
clamp and fork tube and on the outside of the clutch
cable.
b. Route left hand control wires between the lower
clamp and fork tube.
6. Install a new left hand grip.
7. Install front brake master cylinder. See
BRAKE MASTER CYLINDER AND HAND LEVER.
8. Check steering motion range to both fork stops.
2.24
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
installed, the resulting sparks may cause a battery explo-
sion which could result in death or serious injury.
9. Install battery by threading positive cable (red) into
threaded hole first tightening to 72-96 in-lbs (8-11 Nm).
See 1.5 BATTERY
After installing seat, pull upward on front of seat to be
sure it is locked in position. If seat is loose, it could shift
during vehicle operation and startle the rider, causing
loss of control which could result in death or serious
injury.
10. Install seat. See
2.23
2.24 CLUTCH HAND
7.16 HANDLEBAR
D.1 HOSE AND WIRE
2.10 FRONT
11 1
WARNING WARNING
MAINTENANCE.
11 1
WARNING WARNING
2.41 SEAT.
2.27