Fitting Instructions
Bonneville/T100 - Comfort bars fitting instructions
- Remove seat ( 2 x 5mm Allen Head bolts )
- Remove Fuel tank ( 2x 8mm headed bolts at rear of tank) remember to turn fuel tap off before disconnecting fuel line and tank breather
- Loosen Throttle cables but do not remove nipples from throttle shaft
- Remove throttle housing from handlebars and front master cylinder from bars (1 x Phillips screw and 2 x 5mm Allen bolts) Remove the cable retainers in the housing to allow complete removal of cables as you will now have to re-route them.
- Re-route throttle cables under and to the right of the main frame backbone. Thread cables between coil and coil brace, around the steering lock and between the triple clamps.
- Remove clutch cable from clutch lever and engine, remove old handlebars.
- Fit new handlebars. Refit new clutch cable. Refit throttle cables using new routing (Make sure throttle operates freely at full steering lock either side)
- Remove original brake hose and replace with new one. Note torque values for brake hose end fittings (20Nm) and the requirement for loctite on those fittings. (Re-use original brake banjo bolts)
- Bleed brakes and pressure test brake line for any signs of leakage.
- Ensure all fittings are reconnected and torqued and that throttle, brakes and clutch are operating correctly.
- Refit tank and seat.
- Go riding!