Kawasaki Z1000SX - Service manual > Handlebar

Handlebar Removal

• Remove:
  Clutch Lever Clamp Bolts [A]
  Clutch Lever Assembly [B]
  Left Switch Housing [C]
  Handlebar Weight [D]

• Remove:
  Front Master Cylinder [A] (see Front Master Cylinder Removal in the Brakes chapter)
  Right Switch Housing [B]
  Throttle Case [C]
  Handlebar Weight [D]
  Throttle Grip [E]

• Remove:
  Handlebar Bolt [A]
  Handlebar

• Loosen the upper front fork clamp bolt [A].
• Remove:
  Handlebar Holder Bolt [B]
  Handlebar Holder [C]

Handlebar Installation

• Install the handlebar holder on the steering stem head.
• Tighten the handlebar holder bolt [A] and front fork clamp bolt [B].

  Torque -
   Handlebar Holder Bolt: 25 N*m (2.5 kgf*m, 18 ft*lb)
   Upper Front Fork Clamp Bolt: 25 N*m (2.5 kgf*m, 18 ft*lb)

• Apply adhesive cement to the inside of the left handlebar grip.
• Fit the pin [A] of the handlebar to the recess [B] of the handlebar holder.
• Apply a non-permanent locking agent to the threads of the handlebar bolts.
• Tighten:
  Torque - Handlebar Bolts: 34 N*m (3.5 kgf*m, 25 ft*lb)

• Install:
  Front Master Cylinder (see Front Master Cylinder Installation in the Brake chapter)
  Throttle Grip
  Throttle Cable Tips [A]
  Throttle Cases [B]
  • Fit the projection [C] into a hole [D] in the handlebar.
• Apply a non-permanent locking agent to the threads of the handlebar weight bolts, and tighten them.

• Install the clutch lever (see Clutch Lever Installation in the Clutch chapter).
• Install the left and right switch housings.
  • Fit the projection [A] into a hole [B] in the handlebar.

Torque - Switch Housing Screws: 3.5 N*m (0.36 kgf*m, 31 in*lb)

See also: