Polaris EV206PH-B Technical And Service Manual page 7

ChApTEr 2
STEErING ANd SUSpENSION
WArrANTy NOTE: Steering and front suspension fall under "non-electric" component warranty. applicable
warranty is 6 months from date of purchase. any service issue resulting from misuse of bicycle is not
covered under this warranty and user shall be responsible for all charges .
hANdLEBAr rEpLACEmENT
removal
1. note the position of the throttle and the shifter relative to its handlebar grip. If necessary, measure the
gap between each item and its handlebar grip or make a drawing so these components can be reinstalled
with the proper positioning and orientation. also note the orientation of the handlebar within the handlebar
stem.
2. remove the left and right handlebar grip.
3. loosen the throttle set screw (a, figure 2-1), shifter clamp bolt (a, figure 2-2), the reflector clamp bolt
screw, the clamp bolt on each brake lever (b, figure 2-2), and display unit set-screw. (b, figure 2-1)
4. remove the handlebar binder bolts (figure 2-3).
5. lower the handlebar from the handlebar stem.
6. Slide the throttle, shifter, display, brake levers and the reflector assembly from the handlebar ends and
remove the handlebar.
B
A
B
A
8
Servicemanual_101212.indd 8-9
FIGUrE 2-1
FIGUrE 2-2
B
Installation
1. Install the handlebar by reversing the removal procedures.
a. make sure the handlebar is centered and properly oriented within the handlebar stem.
b. apply grease to the handlebar binder bolts (Figure 2-3), and evenly tighten the bolts in a star pattern so
the gap at the top of the clamp is the same as the gap at the bottom. torque the handlebar binder bolts
to the specification in table 5.
c. Slide the reflector, each brake lever, throttle, display, shifter onto their respective handlebar ends.
d. Install handlebar grip onto each handlebar end.
e. position the throttle, shifter and display relative to its handlebar grip as noted during removal. tighten
their set-screws and clamp bolts.
f. Slide each brake lever so its bracket seats against the throttle or shifter. rotate the brake lever to the
position noted during removal, and torque the brake lever clamp bolts to the specification in table 5.
g. rotate the throttle and shifter so their barrels rest against the brake lever. torque the throttle set screw
and the shifter clamp bolt to the specifications in table 5.
hANdLEBAr STEm
removal
1. If necessary, remove the handlebar binder bolts (Figure 2-3), and remove the handlebar from the
handlebar stem. Use a bungee cord to suspend the handlebar from the frame.
2. loosen the handlebar stem bolt from the top of the handlebar stem (a, Figure 2-4). you may remove bolt
and cap.
FIGUrE 2-3
FIGUrE 2-4
C A
B
9
10/12/2012 12:25:47 am