Content Source: 2019 800 Titan Adventure Owner’s Manual (9928876 R01) > The Perfect Fit Chapter

IMPORTANT

The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle.Always follow the warnings and instructions in Owner's Manual.

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Handle Bar Examples

Handlebar Component Fastener Torques

IMPORTANT
Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to secure the component. Do not move a handlebar component without first loosening its mounting screws/set screws. Take care to avoid damaging hand warmer/brake switch wires when moving components.
Image

Component

Torque

Do not over-tighten
Left Handlebar Control Block 20 in-lbs (2.3 Nm)
Brake Lever / Master Cylinder
Torque the front screw first, then torque the screw next to the reservoir.
 70 in-lbs (7.9 Nm)
Upper / Lower Riser Clamps 14.8 ft-lbs (20 Nm)
Throttle Lever Block Set Screw 27 in-lbs (3.1 Nm)
Throttle Lever Block Cover Screws 6 in-lbs (0.7 Nm)
Auxiliary Engine Stop Switch Set Screw 12 in-lbs (1.4 Nm)
Riser Install with the “FWD” stamp facing toward the hood
Not Shown Hand Guard Mounts (if applicable) Hand-Tight
Not Shown Mountain Hoop Bar (if applicable) 10 ft-lbs (13.6 Nm)

Handlebar Component Locations

Refer to the following illustration and measurements to position handlebar components at factory-specified locations.
NOTE
Do not move handlebar components without first loosening the components’ screws.
Image
.039″ (1 mm) 0.13″ (3.3 mm)
0.51″ (13 mm) 0.08″ (2 mm)
10″ (254 mm) 6.65″ (169 mm)

Left Hand Control Alignment

  1. Loosen the brake master cylinder mounting screws and move it away from the left hand control .
    caution
    Take care to avoid damaging hand warmer/brake switch wires when moving components.
    Image
  2. Loosen the four left hand control mounting screws.
  3. Move the control block to the desired position.
    NOTE
    If the control is loose and was inadvertently moved without loosening the screws, move the control block slightly to the left or right to relocate the pins.
  4. Tighten the screws to specification in the sequence shown in the image. Do not over-torque.
    TORQUE
    24 in-lbs (2.7 Nm)
  5. Return the master cylinder to its specified position. Make sure the clamp will not pinch the brake light signal wire. Tighten the clamp screws to specification beginning with the front screw first, then the screw next to reservoir. Do not over-torque.
    TORQUE
    70 in-lbs (7.9 Nm)

Throttle Block Alignment

  1. Slightly loosen the set screw on the bottom of the housing.
    Image
  2. Move the control block to the desired position.
    NOTICE

    Take care to avoid damaging hand warmer wires when moving components.
  3. Tighten the screw to specification. Do not over-torque.
    TORQUE

    27 in-lbs (3 Nm)
  4. With the engine off, test throttle lever movement after tightening the screw. See Throttle Safety Switch.

Engine Stop Switch Alignment

caution
The stop switch must be positioned in an easily accessible location.

  1. Slightly loosen the set screw on the bottom of the housing .
  2. Move the switch to the desired position.
  3. Tighten the screw to specification. Do not over-torque.

Image
TORQUE
12 in-lbs (1.4 Nm)

Riser Angle

Riser angle can be adjusted to suit rider preference.

  1. Loosen the four bolts on the bottom of the adjuster block . If necessary, pry the blocks apart with a screwdriver.
  2. Adjust the riser forward or rearward to the desired position.
  3. Tighten the bolts to 14.8 ft-lbs (20 Nm).

Image

Handlebar Angle

Image
Handlebar angle can be adjusted to suit rider preference.
  1. Loosen the four bolts on the top riser block .
  2. Adjust the handlebar upward or downward to the desired angle. Be sure the handlebar, brake lever and throttle lever operate smoothly and do not hit the gas tank, windshield or any other part of the machine when turned fully to the left or right. If necessary, loosen the set screws for the left and right controls, rotate the controls slightly, then tighten the set screws to the proper torque.
    NOTICE

    Do not stretch wires while adjusting the controls. Stretching the wires could damage the handwarmers.
  3. Tighten the bolts.
    TORQUE

    14.8 ft-lbs (20 Nm)

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