SPECIFICATIONS

Remove the handlebar clamp cover screws, using a 3/16” hex bit, and remove the cover.

Figure 543 — Handlebar clamp cover removal Loosen and remove the mounting screws and clamp securing the brake lever assembly and/or the clutch control assembly, using a 5/32” hex bit. Remove the required assembly and position away from the switch housing.

Figure 544 — Removing brake assembly Separate the right and/or left switch housing from the handlebars and remove the switches from the housing as described under Replacing a Switch Only in this section.

Attach a 3’ length of suitable flexible cable to the module terminal ends of the handlebar harness. From the switch end, carefully pull the wire harness and cable from its routing through the upper fork tube bracket and internally through the handlebar. When the harness terminal ends clear the opening at the handlebar grip, disconnect and remove the harness from the cable. Leave the cable in the handlebar for installation of the harness.

Figure 545 — Harness routing through upper fork bracket Attach the module terminal end of the new harness to the cable. This is a temporary connection. Use care in making this connection by wrapping the terminals to protect them during installation. Using the cable, carefully pull the wire harness internally through the handlebar, through the center slot in the upper fork bracket and up to the electronic control module. Install the second harness in the same manner, if required. Install the wire terminals in the connector block(s) and plug the block(s) into the module. Place the module in the holder, making sure that the lockdown tabs are engaged and the module is secured. Install a new nylon tie strap. Route the harness(es) along the upper frame rail and secure it with tie straps. Install the switches in the respective housing sockets. Then secure the harness to the housing.