Handlebars Inspection; Steering Shaft Removal And Installation - Suzuki kq500 Service Manual

6B-5 Steering / Handlebar:
• Tighten the left handlebar switch screws (6).
• Install the master cylinder. Refer to "Front Brake
Master Cylinder Assembly Removal and
Installation: in Section 4A".
• Align the punch mark "E" on the handlebars with the
mating surface "F" of the throttle lever case.
"E"
• Tighten the throttle lever case bolts (7) to the specified
torque.
Tightening torque
Throttle lever case bolt (c): 4 N·m (0.4 kgf-m, 3.0
lbf-ft)
6
I931H1620040-01
"F"
I931H1620013-02
7
(c)
I931H1620014-04

Handlebars Inspection

Refer to "Handlebars Removal and Installation
(Page 6B-3)".
Inspect the handlebars for distortion or damage.
If any defects are found, replace the handlebars with a
new one.

Steering Shaft Removal and Installation

Removal
1) Remove the EPS control unit. Refer to "EPS
Control Unit Removal and Installation: in Section
6C".
2) Remove the EPS body assembly. Refer to "EPS
Body Assembly Removal and Installation: in
Section 6C".
3) Disconnect the tie-rod ends with the special tool.
Refer to "Front Wheel Hub / Steering Knuckle
Removal and Installation: in Section 2B".
WARNING
!
When using the tie-rod end remover, keep
clear of the tie-rod end because it may come
loose with some force and could strike you.
Special tool
(A): 09942–72410 (Tie-rod end remover)
(A)
B931H26206004
I931H1620038-01
B931H26206005
I931H1620015-01