Handlebars - Buell 2002 S3T Service Manual

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HANDLEBARS

REMOVAL
1. Remove front brake master cylinder. See
BRAKE MASTER CYLINDER.
2. Remove left handlebar switch housing. See
DLEBAR SWITCHES. Cut left handlebar grip and
remove.
3. Detach clutch hand control from handlebars. See
CLUTCH CONTROL.
4. Loosen screws on right handlebar switch housing, but do
not detach throttle grip assembly from handlebar. See
2.24 THROTTLE CONTROL.
5. See Figure 2-86. Remove four screws (1, 2) from handle-
bar clamp (3).
6. Slide handlebars out of throttle grip assembly to remove.
INSTALLATION
1. Slide handlebars into throttle grip assembly. Fasten right
handlebar switch housing to handlebar. See
DLEBARS.
2. Install clutch hand control. See
TROL.
3. See Figure 2-87. Install handlebar clamp.
a. Route right hand control wires (1) under handlebar
and in front of fork tube (4) and handlebar clamp (3).
b. Route left hand control wires (2) under handlebar
and in front of fork tube (4) and handlebar clamp (3).
c. See Figure 2-86. Tighten both front screws (1) to 10-
12 ft-lbs (14-16 Nm).
d. Then tighten both rear screws (2) 10-12 ft-lbs (14-
16 Nm).
4. Install left switch housing. See
SWITCHES
5. Install a new left handgrip.
a. Clean end of handlebar with M600.
b. Place LOCTITE 411 ADHESIVE around inside of
grip.
c. Push grip onto handlebar end. Twist grip on bar until
end touches left switchgear housing.
d. Wipe off excess adhesive with a rag.
6. Install front brake master cylinder. See
BRAKE MASTER CYLINDER.
7. Check steering motion range to both fork stops. See
STEERING HEAD BEARINGS.
2.10 FRONT
7.5 HAN-
2.25
2.26 HAN-
2.25 CLUTCH CON-
7.5 HANDLEBAR
2.10 FRONT
1.16
6286
3
1. Front Clamp Screws (2)
2. Rear Clamp Screws (2)
3. Handlebar Clamp
Figure 2-86. Handlebar Clamp
6287
4
1
5
6
1. Right Hand Control Cables
2. Left Hand Control Cables
3. Handlebar Clamp on Upper Triple Clamp
4. Fork Tube
5. Front Brake Line
6. Throttle Cables
Figure 2-87. Routing Hand Control Wires
2002 Buell S3T: Chassis
2.26
1
2
3
2
2-55