Suzuki Burgman 400 - Service manual > Steering / Handlebar

Repair Instructions

Handlebars Components

1. Throttle grip
2. Rubber grip
3. Handlebar switch box (RH)
4. Handlebar switch box (LH)
5. Rear view mirror
6. Handle cover
7. Handlebar holder
8. Handlebar
9. Handle expander
10. Handle balancer expander

1. Apply handle grip bond.

: Apply thread lock to thread part.

1. : 23 N*m (2.3 kgf-m, 16.5 lb-ft)
2. : 10 N*m (1.0 kgf-m, 7.0 lb-ft)

Handlebars Removal and Installation

Removal

Remove the handlebar cover. Refer to "Handlebar Cover Removal and Installation".

Left side

1) Remove the rear view mirror (1).

2) Disconnect the rear brake light switch lead wire couplers (2).

3) Remove the rear brake master cylinder (3).

! CAUTION Do not turn the rear brake master cylinder upside down.

4) Remove the left handlebar switch box (4).

5) Remove the handlebar balancer (5).

6) Remove the grip rubber (6).

Right side

1) Remove the rear view mirror (1).

2) Disconnect the front brake light switch lead wire couplers (2).

3) Remove the front brake master cylinder (3).

! CAUTION Do not turn the front brake master cylinder upside down.

4) Remove the right handlebar switch box (4).

5) Remove the handlebar balancer (5).

6) Remove the throttle grip (6).

Handlebar holder

1) Remove the handlebar clamp bolts (1).

2) Remove the handlebar holder (2).

3) Remove the handlebars (3).

! CAUTION Hold the handlebar by the hand to prevent throw or drop out of the steering stem.

Installation

Install the handlebars in the reverse order of removal.

Pay attention to the following points:

• Set the handlebars so that its punch mark "A" aligns with the mating surface of the left handlebar holder.

• Apply thread lock to the handlebar clamp bolts.
• Tighten the forward handlebar clamp bolts first temporarily to provide clearance on the rear side and then tighten both the bolts to the specified torque.

: Thread lock cement 99000-32030 (Thread Lock Cement Super 1303 or equivalent)

Tightening torque
Handlebar clamp bolt (a): 23 N*m (2.3 kgf-m, 16.5 lb-ft)

NOTE First tighten the handlebar clamp bolts (front ones) to the specified torque.

1. Clearance

• After installing the steering, the following adjustments are required before driving.
  • Cable routing (Refer to "Throttle Cable Routing Diagram ").
  • Throttle cable play (Refer to "Throttle Cable Play Inspection and Adjustment").

Right side

• Install the right handlebar switch box (1) to the handlebars by engaging the stopper "A" with the hole "B" on the handlebars.
• Adjust the throttle cable play. Refer to "Throttle Cable Play Inspection and Adjustment ".

• Install the brake master cylinder onto the handlebars, align the master cylinder holder's mating surface with punch mark "C" on the handlebars.
• Tighten the upper bolt first temporarily to provide clearance on the lower side and then tighten both the bolts to the specified torque.

Tightening torque
Master cylinder bolt (a): 10 N*m (1.0 kgf-m, 7.0 lb-ft)

• Connect the front brake light switch lead wire couplers.

Left side

• Install the left handlebar switch box (1) to the handlebars by engaging the stopper "A" with the hole "B" on the handlebars.

• Install the brake master cylinder onto the handlebars, align the master cylinder holder's mating surface with punch mark "C" on the handlebars.
• Tighten the upper bolt first temporarily to provide clearance on the lower side and then tighten both the bolts to the specified torque.

Tightening torque
Master cylinder bolt (a): 10 N*m (1.0 kgf-m, 7.0 lb-ft)

• Connect the rear brake light switch lead wire couplers.
• Apply a handle grip bond "D" onto the left handlebar before installing the handlebar grip.

: Handle grip bond (Handle grip bond (commercial available) )

See also: