Handle Bar Examples

Content Source: 2020 600/800 HO/850 AXYS Conventional Tunnel Owner’s Manual (9929775 R02) > 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.

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

Handlebar angle can be adjusted to suit rider preference.

Loosen the four bolts on the top riser block .

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.

Tighten the bolts.

TORQUE
14.8 ft-lbs (20 Nm)

Riser Angle

Riser angle can be adjusted to suit rider preference.

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

Adjustable Riser (if equipped)

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

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

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

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.

Loosen the four left hand control mounting screws.

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.

Tighten the screws to specification in the sequence shown in the image. Do not over-torque.

TORQUE
24 in-lbs (2.7 Nm)

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.

.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)