| Author | Message | ||
     Rombi |
I have searched and have read a lot about installing the bars. I bought a used set and it did not have the instructions (which I gather do not give much helpfull info) What tools are needed that are not in the tool kit? I am talking about other than "normal tools". I have all kinds of sockets and wrenches but is there certain drivers that I will need? The star type or whatever I guess. I want to have all the tools so when I dive in I don't have to run to borrow something. Also is anyone that has kind of a step by step like the noid issue? Like I said I have searched and found very good info like the video of the cable routing but not much else. I use to be a jet mechanic in the air force and I swear I am more intimidated diving into this bike than I was a F-15. Thanks, Tom Thanks, Tom | ||
| Usanigel |
I only got the parts and no instructions. So here's what I remember. Remove the seat, remove the "tank" cover, remove the headlight top piece. Remove the air box lid, remove the air filter. carefully remove the air box lower section because there will be some grit in it. This is a little tricky because of the tight fit around the throttle bodys. Best to carefully remove and unhook the mirrors. Next unbolt the front brake line at the lowest point, catch the brake fluid. wipe off any spills. Next the clutch line at the lowest point. It will dribble for a while. Undo the switch pack from the left side. Undo the right side with the throttle cables. Unbolt front brake line from the reserve and front fork. Watch for drip of brake fluid. Remove front brake lever assembly. Remove clutch line and clutch lever assembly. Don't remove the line from the frame yet. Swap over the handle bars, go by the white lines. Next is the throttle cables, check where they run, its important for best operation of the longer ones, disconnect and install the new cables starting at the back of the headlight and threading up to the throttle bodies. Take the same route as the old ones. Connect to the throttle bodys. Black lock nuts are on the return. Next thread the cables up to the handlebars and install the throttle grip. Check for binding at full lock. Left seems to be where most problems are. Get this working right, even if it takes some time. Install the front brake lever assembly. Some rearranging of the wires inside the headlamp housing will give enough slack to connect the front brake wires. Install clutch lever assembly. Install clutch side switches. Install new front brake line. Install new clutch line following the same route as the old. (tight fit in places) Bleeding the lines. Remove the cap to the reservoir and ease the bellows flat again. pour in some DOT4. Next you need some clear tubing and a bottle. install the tubing on the bleed nipple, Open the bleed nipple and let the fluid run through into the bottle, it will slowly. DON'T squeeze the lever without a lid on! Topup and place the lid on. squeeze the lever with the nipple open. Hold the lever and close the nipple. let go the lever, squeeze the lever and open the nipple, repeat until no more bubbles. keep an eye on the brake fluid level. Do the same with the clutch line. Reinstall the mirrors rerouteing the wires where needed. Check all the cables for easy working and no chance of rubbing. make sure all the electrics are working. Check again with full lock, both ways! Reinstall all the body work. A wipe of lube on the intake rubber will help to install it. There are pins to locate the grips. Replace wire ties where needed. That's all I can remember! | ||
| Rombi |
Thanks, I know it feels more daunting than it is. I guess I will de-noid the bike as long as I am in there. So there is no special tools I will need? Can someone fix that RHigh bar title for me please? | ||
| Brumbear |
And when your cables stick just search the issue there is a million posts on that as well  |
