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post #1 of 161 (permalink) Old 02-05-2011, 06:31 PM Thread Starter
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FBW Handle Bar Install w/ Pics

Ok so I finally took the plunge and tore my bike into a jillion peices and did the handle bar install. I went in blind, with very little research, no instructions, just started taking it down untill I figured it all out. My good camera was MIA during the install but I took pics along the way. There is even good pics of the fairing removal for those of you who are still un easy about that project!

All in all, it was not too nad at all. It went smooth, only advise is take your time, and COVER YOU BIKE!!! Every inch of it! I had mine covered untill the last minute when I was doing final adjustments and dropped a wrench on my tank leaving a very small but noticable scratch down to the metal! UGHHH I was pissed. Ok so here we go with the install.

Here is a pic of every single tool I used to complete this project. Not to much stuff, from left to right: butter knife, adjustable wrench, socket wrench, very small flat head screw driver, T-20,T-25,T-27,T-30 torx head sockets, 13mm or 1/2inch box wrench, needle nose pliers, and somewire cutters. Thats it!


Ok first thing is look on each side of your speedo and tach guages, there are torx head screws on each side (T-20). Take them out and give the guages a good tug and the guages will come off.

Next, pull the guages out and try to make some sense of the wire coming from the back of the guages. This is what you should see.
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post #2 of 161 (permalink) Old 02-05-2011, 06:46 PM Thread Starter
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Next unplug the connectors from the back of the tach and speedo guages. there is one for each guage. You can mark them if you wish but they are not the same plug, or interchangable, so you can not mix them up. I did not get a pic of unplugging the guages, but If you dont know how then stop, load your bike on a trailer, and take it to you nearest stealer, and fork over 9 hours worth of labor to have your bars installed. This project is not for you! LOL... just kidding, you can do it, this is not hard!

Next is the removal of the ignition switch. I think someone posted a great video of how to do this but I will how the pics here. Simply feel under the back side of the switch and fing this little button:

Push that button up towards you, then while holding the button up, push down on the entire switch. Once you push down, you will hear a click, you can now pull up on the switch and it will come out.

Next grab your adjustable wrench and where you just pulled the switch out, there will be a silver bolt on top of the ignition shaft, take that bolt off, then a weird looking washer looking thing under it, and a black washer under that. take all of them off and remember how they came off... or refer to this pic:

Next pull up on the cover plate that has the words Lock, Off, ignition, Acces. it pulls off very easily.
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post #3 of 161 (permalink) Old 02-05-2011, 06:53 PM Thread Starter
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Next, look down the side of your upper forks (inside the hole in the fairing between the tank and the back of the inner fairing. You will see two bolts holding the black shroud onto the forks. Remove these 4 bolts (T-30)


Now back up to where your guages used to be.... the two halfs of the guage cover is snapped together, just pull on each side vey gently and they will separate:


It is not completley neede to remove the covers, but it will give you more room to work with. You have to turn the handle bars a little bit but they come out like a puzzle. I removed mine:
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post #4 of 161 (permalink) Old 02-05-2011, 07:01 PM Thread Starter
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Next thing is to remove the switch covers from your handle bars. On the clutch side remove the bolt on top and bottom of the switch housings (T-25)
Top:


Bottom:


Then use a (T-27) and remove the bolts hold the clutch perch:
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post #5 of 161 (permalink) Old 02-05-2011, 07:03 PM Thread Starter
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Lay the clutch on your fairing and let the switches hang for now. Thay wont go anywhere yet.


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post #6 of 161 (permalink) Old 02-05-2011, 07:05 PM Thread Starter
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Now repeat for the throtle side Same procedure, and same torx bits:




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post #7 of 161 (permalink) Old 02-05-2011, 07:08 PM Thread Starter
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Lay a cloth or rag over your throtle side glove box on the fairing, and lay the brake cylinder assembly on it. It stays pretty well, but keep an eye on it. DO not want to shake it around to much. Let the switches hang like the other side. We will get them off in a few.

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post #8 of 161 (permalink) Old 02-05-2011, 07:36 PM Thread Starter
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While you are on the throtle side, do the easist part of the whole install.... slide the grip off... easy cheezy.



Now go to the clutch side and take off that grip. Grab it really hard with both hands. Twist violently in both directions untill the glue breaks free and the grip slides off. Now look at how red your hands are.... That sucked! Or if you have new grips, grab a razor blade and cut that thing off. Either way you dont need it on the bars anymore. I had to reuse mine to I went with the painful way of taking it off.

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post #9 of 161 (permalink) Old 02-05-2011, 08:00 PM Thread Starter
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Now it is time to remove the outter fairing. There are three bolts (T-25) on each side of the fairing (6 total) Remove them. Here is where they are located:







The bolts are in the exact same place on the other side of the fairing. Sorry no Pics.
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post #10 of 161 (permalink) Old 02-05-2011, 08:04 PM Thread Starter
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Now go to your front turn signals. Look inside the fairing, and find the two chrome bolts that hold the turn signals on. Remove them ( 13mm open end or box wrench also a 1/2 inch works)



Another pic



Now just pull the turn signal off and let it hang. Do the same for the other turn signal.

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