Yamaha XMAX YP125R - Service manual > Handlebar

Removing the handlebar

Removing the handlebar

Removing the handlebar

1. Stand the vehicle on a level surface.

WARNING

Securely support the vehicle so that there is no danger of it falling over.

2. Remove:

• Handlebar grip "1"

TIP

Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

Checking the handlebar

1. Check:

• Handlebar

Bends/cracks/damage → Replace.

WARNING

Do not attempt to straighten a bent handlebar as this may dangerously weaken it.

Installing the handlebar

1. Stand the vehicle on a level surface.

WARNING

Securely support the vehicle so that there is no danger of it falling over.

2. Install:

• Handlebar
• Upper handlebar holders

Upper handlebar holder bolt 23 Nm (2.3 m*kgf, 17 ft*lbf)

NOTICE

First, tighten the front bolt on each handlebar holder, then the rear bolt.

TIP

The upper handlebar holders should be installed with the arrow marks "a" facing forward "A".

3. Install:

• Handlebar grip

a. Apply a thin coat of a rubber adhesive to the left end of the handlebar.

b. Slide the handlebar grip over the left end of the handlebar.

c. Wipe off any excess rubber adhesive with a clean rag.

WARNING

Do not touch the handlebar grip until the rubber adhesive has fully dried.

4. Install:

• Left handlebar switch "1"

TIP

Align the projection "a" on the left handlebar switch with the hole "b" in the handlebar.

5. Install:

• Rear brake master cylinder "1"
• Rear brake master cylinder holder

Brake master cylinder holder bolt 7 Nm (0.7 m*kgf, 5.1 ft*lbf)

TIP

• Align the projection "a" on the brake master cylinder with the hole "b" in the handlebar.
• First, tighten the front bolt, then the rear bolt.

6. Install:

• Throttle grip "1"
• Throttle cables "2"
• Right handlebar switch "3"

TIP

• Be sure to position the washer between the throttle grip and the right handlebar switch.
• Lubricate the end of the throttle cables and the inside of the throttle grip with a thin coat of lithium- soap-based grease.
• Align the projection "a" on the right handlebar switch with the hole "b" in the handlebar.
• Be sure to slide the throttle cable rubber cover to its original position.

7. Install:

• Front brake master cylinder "1"
• Front brake master cylinder holder

Brake master cylinder holder bolt 7 Nm (0.7 m*kgf, 5.1 ft*lbf)

TIP

• Align the projection "a" on the brake master cylinder with the hole "b" in the handlebar.
• First, tighten the front bolt, then the rear bolt.

8. Adjust:

• Throttle cable free play

Throttle cable free play 3.0-5.0 mm (0.12-0.20 in)

See also: