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.
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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 Angle

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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)

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).

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Adjustable Riser (if equipped)

To adjust the riser (if equipped), do the following:

  1. Release the riser clamp .
  2. Adjust the handlebar upward or downward to the desired height.
  3. Secure the riser clamp .

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Periodically inspect the torque of the upper/lower handlebar clamp fasteners, and slide fasteners.
TORQUE
Handlebar Clamp Fastener Torque:
16 ft-lbs (21 Nm)
ROX Slide Fastener Torque:
16 ft-lbs (21 Nm)
Adjuster Cranks:
Hand Tight

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)

Handlebar Components

Refer to the following illustration and measurements to position handlebar components at factory-specified locations.
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  • .011 in. (3 mm)
  • 6.65 in. (169 mm)
  • 6.7 in. (170 mm)

  • 10 in. (254 mm)
  • .47 in. (12 mm)
  • .08 in. (2 mm)

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