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For those who have crashed their r15, bent handlebar can be frequent problem. Some of you might have paint scraped off after years, like me. Either way you will need to take handlebars overhauled for painting or replacement or maybe you need to replace one of those handlebar switch controls assy.
Read in DIY request thread few months back, I painted mine black and took the pics of process.
LEFT HAND SIDE HANDLEBAR
1) Remove clutch lever and the wire by using 10mm T socket as shown.
2)Now remove the clutch switch socket from the plug as shown.
3) Now remove the clutch lever holder as shown. Its a 10mm bolt, same as clutch one in step 1. Remove that section if you can ,prying it wide open or leave it for now, read on, there is another way, I pried it wide open and took it off (not preferred).
4)Removing bar end is easy, some people just use brute force and pull it out. I prefer holding it with pliers and then use the allen key from tool kit to remove the middle allen bolt.
5)Now remove the two allen bolts as shown, I guess both allen keys are provided in the tool kit. One is pinch bolt and other one locks the clip-on on the upper plate. Then lift off the handle bar.
6)Now we remove the handlebar controls assy, just two Philips screws. After taking handlebar off, look underneath them, open two marked Philips screw and then lift off the controls assy out, put the screw back in so you won't loose them and put the assy on dashboard while you continue. I removed everything and kept it aside as shown in next step.
7)Now remove the grip by sliding it across the end of handlebar and take it out. Now you take out the 'clutch lever holder' I talked about in step 3 slide it across the grip section to the end of handlebar and then out. The final look should be something like this..
Reversal is tricky, you need to slide the clutch holder section in, then slide the grips on. Fit the bar ends by allen bolts, then fit the handlebar controls. Fit the handlebar back on the top plat and fork top section. Tighten the allen bolts and then fit clutch lever on holder with holder bolt still loose, check which angle seems perfect to you, tighten the holder and put the clutch wire back in.
RIGHT HAND SIDE HANDLEBAR
1)Remove the bar end first as you did on left hand side handlebar, refer above.
2)now remove the two marked bolts using a 8mm T socket. This will take whole front brake assembly off, the brake lever and master cylinder. Keep the bracket somewhere safe. Brake lever can also be removed by removing the 10mm bolt near master cylinder.
3)Now open up the two handlebar main allen bolts just as we did on left hand side.
4) Now see below the controls, just as on the left hand side ones, this side too has 2 philips screws. Remove them and loosen the controls, remember not to take them off as the kill switch red wires will be connected to top bucket, take it out carefully. The throttle wire is just as a clutch wire, when you will open it up you will have a rough idea of how that goes, its really simple. Now remove the throttle grip sliding across then end.
Reversal of this one is simple.
Tools used would be
10mm T socket
8mm T socket
6mm allen key
8mm allen key
philips screw driver
plier normal ones
plier for holding the bar ends
Did it in hurry, couldn't take more detailed pics. Hope this helps....
further inputs appreciated folks.
Read in DIY request thread few months back, I painted mine black and took the pics of process.
LEFT HAND SIDE HANDLEBAR
1) Remove clutch lever and the wire by using 10mm T socket as shown.
2)Now remove the clutch switch socket from the plug as shown.
3) Now remove the clutch lever holder as shown. Its a 10mm bolt, same as clutch one in step 1. Remove that section if you can ,prying it wide open or leave it for now, read on, there is another way, I pried it wide open and took it off (not preferred).
4)Removing bar end is easy, some people just use brute force and pull it out. I prefer holding it with pliers and then use the allen key from tool kit to remove the middle allen bolt.
5)Now remove the two allen bolts as shown, I guess both allen keys are provided in the tool kit. One is pinch bolt and other one locks the clip-on on the upper plate. Then lift off the handle bar.
6)Now we remove the handlebar controls assy, just two Philips screws. After taking handlebar off, look underneath them, open two marked Philips screw and then lift off the controls assy out, put the screw back in so you won't loose them and put the assy on dashboard while you continue. I removed everything and kept it aside as shown in next step.
7)Now remove the grip by sliding it across the end of handlebar and take it out. Now you take out the 'clutch lever holder' I talked about in step 3 slide it across the grip section to the end of handlebar and then out. The final look should be something like this..
Reversal is tricky, you need to slide the clutch holder section in, then slide the grips on. Fit the bar ends by allen bolts, then fit the handlebar controls. Fit the handlebar back on the top plat and fork top section. Tighten the allen bolts and then fit clutch lever on holder with holder bolt still loose, check which angle seems perfect to you, tighten the holder and put the clutch wire back in.
RIGHT HAND SIDE HANDLEBAR
1)Remove the bar end first as you did on left hand side handlebar, refer above.
2)now remove the two marked bolts using a 8mm T socket. This will take whole front brake assembly off, the brake lever and master cylinder. Keep the bracket somewhere safe. Brake lever can also be removed by removing the 10mm bolt near master cylinder.
3)Now open up the two handlebar main allen bolts just as we did on left hand side.
4) Now see below the controls, just as on the left hand side ones, this side too has 2 philips screws. Remove them and loosen the controls, remember not to take them off as the kill switch red wires will be connected to top bucket, take it out carefully. The throttle wire is just as a clutch wire, when you will open it up you will have a rough idea of how that goes, its really simple. Now remove the throttle grip sliding across then end.
Reversal of this one is simple.
Tools used would be
10mm T socket
8mm T socket
6mm allen key
8mm allen key
philips screw driver
plier normal ones
plier for holding the bar ends
Did it in hurry, couldn't take more detailed pics. Hope this helps....
further inputs appreciated folks.
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