Honda CBR125RW - Service manual > Handlebars

REMOVAL

Remove the rearview mirrors.

Hold the handlebar weight and remove the screw, then remove both handlebar weights.

Disconnect the brake light switch connectors.

Keep the brake master cylinder upright to prevent air from entering the hydraulic system.

Remove the bolts, holder and master cylinder.

Remove the screws.

Separate the throttle housing.

Disconnect the throttle cable from the throttle pipe, then remove the throttle pipe.

Remove the grip rubber, replace it if necessary.

Disconnect the clutch switch connectors.

Remove the bolts, holder and clutch lever bracket.

Remove the screws and separate the left handlebar switch housing.

Remove the left handlebar grip rubber.

Remove the stopper rings from both fork pipes.

Loosen the handlebar pinch bolts and remove the handlebars.

INSTALLATION

NOTE:

Route the wires, hose and cable properly.

Install the handlebars to both fork pipes while aligning the bosses on the handlebars with the cut outs on the top bridge.

Tighten both handlebar pinch bolts to the specified torque.

TORQUE: 27 N-m (2.8 kgf-m, 20 lbf-ft)

Install the stopper rings to the grooves of both fork pipes.

Clean the inside surface of the handlebar grip and outside surface of the handlebar and throttle pipe.

Apply Honda Bond A or equivalent to the inside surface of the grips and to the clean surface of the left handlebar and throttle pipe.

Allow the adhesive to dry for 1 hour before using.

Wait 3 - 5 minutes and install the grip.

Rotate the grips for even application of the adhesive.

Install the left handlebar switch housing while aligning the locating pin in the housing with the hole in the handlebar.

Install the screws and tighten the forward screw first, then tighten the rear screw.

Install the clutch lever bracket, holder ("UP" mark facing up) and bolts.

Align the end of the clutch lever bracket with the punch mark on the handlebar, and tighten the upper bolt first, then the lower bolt.

Connect the clutch switch connectors.

Apply grease to the throttle pipe sliding area of the right handlebar.

Install the throttle pipe to the right handlebar.

Connect the throttle cable end to the throttle pipe.

Install the right handlebar switch housing while aligning its locating pin with the hole on the handlebar.

Install the screws and tighten the forward screw first, then tighten the rear screw.

Install the master cylinder, holder ("UP" mark facing up) and bolts.

Align the end of the master cylinder with the punch mark on the handlebar and tighten the upper bolt first, then the lower bolt.

Connect the brake light switch connectors.

Install the handlebar weight to both handlebars aligning with each handlebar and handlebar weight cutout.

Hold the handlebar weight.

Install and tighten new screw to the specified torque.

TORQUE: 9.0 N-m (0.9 kgf-m, 6.6 lbf-ft)

Install the rearview mirrors.

Adjust the following:

• Clutch lever freeplay
• Throttle grip freeplay

INNER WEIGHT REPLACEMENT

Remove the throttle pipe or grip rubber from the handlebar.

Straighten the weight retainer tab by the screwdriver or punch.

Apply lubricant spray through the tab locking hole to the rubber cushions for easy removal.

Temporarily install the handlebar weight and screw, then remove the inner weight assembly by turning the handlebar weight.

Remove the screw, handlebar weight, retainer ring and rubber cushions from the inner weight.

Install the rubber cushions and new retainer onto the inner weight.

Install the handlebar weight to the inner weight, aligning with each cut-outs of the inner weight and handlebar weight.

Install and tighten a new handlebar weight screw.

Install the inner weight assembly into the handlebar.

Turn the inner weight and hook the weight retainer tab with the tab locking hole in the handlebar.

See also: