Triumph Street Triple S - Service manual > Handlebars - Daytona 675

Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Removal

Note:

• This procedure describes the removal of both handlebars.

1. Remove the seat and disconnect the battery negative (black) lead first.

2. Remove and discard the fixings and remove the end weights from the handlebars.

3. Undo the screws and free the left switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside.

4. Unscrew the bolts and remove the clamp from the clutch lever assembly. Without disconnecting the clutch cable, lay the lever aside.

5. Slide off the rubber boot and release the screws which secure the two halves of the twist grip guide to each other.

1. Throttle grip guide
2. Screws
3. Rubber boot

6. Note the position of the guide relative to the handlebar then separate the two halves of the twist grip guide.

7. Note and mark the position of each cable relative to the twist grip in order to correctly identify their location during reassembly.

8. Release the inner cables from the twist grip.

1. Opening cable
2. Closing cable

9. Slide the twist grip off the handlebar.

10. Undo the screws and free the right hand switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside.

11. Unscrew the bolts and remove the clamp from the front brake master cylinder. Taking care to not invert the brake fluid reservoir, lay the assembly aside.

12. Release the fixing securing each handlebar to the top yoke.

1. Handlebar (right hand shown)
2. Fixing

13. Remove the headstock top nut.

1. Headstock top nut

14. Slacken the handlebar and top yoke clamp bolts.

1. Handlebar clamp bolt
2. Top yoke clamp bolt

Caution: Care must be taken when removing the top yoke or handlebars to ensure that the outer surfaces of the front forks do not become scratched.

15. Slide the top yoke off the front forks and lay aside.

16. Slide the handlebars off the front forks.

17. If required, remove the left hand handlebar grip.

18. If the handlebar end weight assembly is to be removed, gently squeeze the clip with suitable pliers and withdraw the assembly from the handlebar.

1. Fixing
2. End weight
3. Clip
4. Damper
5. Internal weight
6. Handlebar

Installation

1. If the bar end weight assembly has been removed from the handlebar, fit a new clip and install the weight into the handlebar. Ensure the two locking tangs on the clip engage fully into the holes in the handlebar.

2. Refit the handlebars to the front forks. Do not tighten the clamp bolts at this stage.

3. Refit the top yoke. Do not tighten the clamp bolts at this stage.

4. Refit the headstock top nut and tighten to 90 Nm.

5. Install the handlebar to top yoke fixings and tighten to 5 Nm.

6. Tighten the top yoke clamp bolts to 26 Nm.

7. Tighten the handlebar clamp bolts to 26 Nm.

8. If removed fit the left hand handlebar grip.

9. Position the clutch lever to the handlebar. Fit the clamp ('UP' arrow pointing upwards) and clamp bolts.

10. Align the split line of the clutch lever with the punch mark on the upper surface of the handlebar, then tighten the clamp bolts, upper first, to 12 Nm.

11. Align the left hand switch cube to the handlebar and secure with the screws. Tighten the screws to 3 Nm.

12. Slide the twist grip onto the right hand side of the handlebar.

13. Reconnect the inner throttle cables as noted during removal. Ensure that the positions of the opening and closing cables are not transposed.

1. Opening cable
2. Closing cable

14. Assemble the two halves of the cable guide ensuring that the outer cables are correctly located in the guide and the guide is positioned on the handlebars as noted prior to removal.

1. Throttle grip guide
2. Rubber boot
3. Screws

15. Tighten the cable guide fixings to 4 Nm.

16. Position the right hand switch cube to the handlebar and tighten the fixings to 3 Nm.

17. Position the front brake master cylinder assembly to the handlebar. Fit the clamp ('UP' arrow pointing upwards) and clamp fixings.

18. Align the split line of the master cylinder clamp to the punch mark on the upper surface of the handlebar and tighten the clamp fixings to 12 Nm.

19. Fit the handlebar end weights, fit new fixings and tighten to 5 Nm.

20. Check the throttle cable free play setting. Adjust as necessary.

21. Reconnect the battery, positive (red) lead first.

22. Refit the seat.

23. Check for correct operation of the front brake and clutch. Check that the throttle opens and closes without sticking and that the cables do not bind or restrict the steering when the handlebars are turned from lock-to-lock. Rectify as necessary.

Warning: Operation of the motorcycle with incorrectly adjusted, incorrectly routed or damaged throttle cables could interfere with the operation of the brakes, clutch or the throttle itself. Any of these conditions could result in loss of control of the motorcycle and an accident.

Warning: Move the handlebars to left and right full lock while checking that cables and harnesses do not bind or that the steering feels tight or difficult to turn. A cable or harness that binds, or steering that is tight/difficult to turn will restrict the steering and may cause loss of control and an accident.

Handlebars - Street Triple and Street Triple R

Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.

Removal

1. Remove the seat and disconnect the battery negative (black) lead first.

2. Undo the fixing screws and remove the end weights from the handlebars.

3. Undo the screws and free the left switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside.

4. Unscrew the bolts and remove the clamp from the clutch lever assembly. Without disconnecting the clutch cable, lay the lever aside.

5. Slide off the rubber boot and release the screws which secure the two halves of the twist grip guide to each other.

1. Twist grip
2. Twist grip guide
3. Screws

6. Note the position of the guide relative to the handlebar then separate the two halves of the twist grip guide.

7. Note and mark the position of each cable relative to the twist grip in order to correctly identify their location during reassembly.

8. Release the inner cables from the twist grip.

1. Closing inner cable
2. Opening inner cable

9. Slide the twist grip off the handlebar.

10. Undo the screws and free the right hand switch gear assembly from the handlebar. Without disconnecting any wiring, lay the switch aside.

11. Street Triple R only: Remove the fixing and detach the front brake fluid reservoir from the mounting bracket. Ensure the reservoir is supported in an upright position.

12. Unscrew the bolts and remove the clamp from the front brake master cylinder. Taking care to not invert the brake fluid reservoir, lay the assembly aside.

13. Release the fixings securing the handlebar clamps to the risers, detach the clamps and collect the handlebar.

1. Upper Clamp
2. Handlebar
3. Riser

14. Remove the left hand handlebar grip.

Installation

1. Locate the handlebar in the lower halves of the clamps. Fit the upper clamps and bolts.

Note:

• The Street Triple has a punch mark for the alignment of the handlebar.
• The Street Triple R has an etched cross mark for the alignment of the handlebar.

2. Align the handlebar mark with the front right hand split line of the clamp/riser, then tighten the front clamp bolts to 26 Nm, then the rears.

1. Right hand front clamp split line
2. Handlebar punch mark (Daytona 675 shown)

3. Fit the left hand handlebar grip.

4. Position the clutch lever to the handlebar. Fit the clamp ('UP' arrow pointing upwards) and clamp bolts.

5. Align the split line of the clutch lever with the punch mark on the upper surface of the handlebar, then tighten the clamp bolts, upper first, to 15 Nm.

6. Align the left hand switch cube to the handlebar and secure with the screws. Tighten the screws to 3 Nm.

7. Slide the twist grip onto the right hand side of the handlebar.

8. Reconnect the inner throttle cables as noted during removal. Ensure that the positions of the opening and closing cables are not transposed.

1. Closing inner cable
2. Opening inner cable

9. Assemble the two halves of the cable guide ensuring that the outer cables are correctly located in the guide and the guide is positioned on the handlebars as prior to removal.

1. Twist grip
2. Twist grip guide
3. Screws

10. Tighten the cable guide fixings to 4 Nm.

11. Position the right hand switch cube to the handlebar and tighten the fixings to 4 Nm.

12. Position the front brake master cylinder assembly to the handlebar. Fit the clamp ('Up' arrow pointing upwards) and clamp fixings.

13. Align the split line of the master cylinder clamp to the mark on the upper surface of the handlebar and tighten the clamp fixings to 15 Nm.

14. Street Triple R only: Attach the front brake reservoir to its mounting bracket. Tighten the fixing to 7 Nm.

15. Fit the handlebar end weights, tightening the fixings to 5 Nm.

16. Check the throttle cable free play setting. Adjust as necessary.

17 Reconnect the battery, positive (red) lead first.

18. Refit the seat.

19. Check for correct operation of the front brake and clutch. Check that the throttle opens and closes without sticking and that the cables do not bind or restrict the steering when the handlebars are turned from lock-to-lock. Rectify as necessary.

Warning: Operation of the motorcycle with incorrectly adjusted, incorrectly routed or damaged throttle cables could interfere with the operation of the brakes, clutch or the throttle itself. Any of these conditions could result in loss of control of the motorcycle and an accident.

Warning: Move the handlebars to left and right full lock while checking that cables and harnesses do not bind or that the steering feels tight or difficult to turn. A cable or harness that binds, or steering that is tight/difficult to turn will restrict the steering and may cause loss of control and an accident.

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