Safety; Intended Use; Safety Instructions; Installation - Gazzini 10039168 Mode D'emploi

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assembly or operation.
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3 | Safety

3.1 | Intended use

The handlebar can be used as an OEM replacement or to give your bike a new look. The handlebar
can be registered in the vehicle documents in Germany following individual test centre approval,
based on the TÜV inspection report regarding its strength. To have the conversion approved, for
which a fee is payable, you need to arrange an appointment with an authorised test centre (e.g.
TÜV, Dekra, GTÜ). The vehicle registration office must then update the motor vehicle registration
certificate (also for a fee). Before installing the handlebar, also make sure that it can be properly
used on your motorcycle without any problems - particularly if your bike has already been modified
previously in the area of the handlebar / handlebar clamps / triple tree / control cables / windshield
/ fairing / other cables. The diameter of the handlebar is 28.6 mm in the area of the clamps, and
22 mm at the ends. It is imperative that you follow the instructions in your owner's manual and the
motorcycle manufacturer's specifications.
The handlebar must only be used as described in these instructions. Any other use is considered
improper use and can result in material damage. The manufacturer and supplier accept no liability
for damage caused by improper or incorrect use.

3.2 | Safety instructions

WARNING!
Danger to children and persons with reduced physical, sensory
or mental abilities (e.g. partially disabled persons, elderly persons with reduced
physical and mental abilities) or lack of experience and knowledge (e.g. older
children)!
• The packaging film must be kept away from children, as there is a risk of
asphyxiation.
CAUTION!
Risk of injury!
• Before you do anything, make sure that your motorcycle is stable and the
workplace well lit to prevent injuries when removing the old handlebar and
fitting the new one.
• Before you start drilling, make sure the handlebar and drilling jig (if used) are
tightly clamped so that they cannot shift. Wear protective goggles.
• Only install the handlebar yourself if you have the necessary technical
knowledge. Otherwise it is essential to have this job done by a qualified
motorcycle workshop.
• Always replace a handlebar that is damaged as a result of an accident.
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IMPORTANT!
Risk of damage!
• Make sure that the handlebar is the right fit for the existing handlebar clamps,
switch units and cables.
• The cables must always be installed correctly so that they cannot be put under
any tension by the handlebar, even when the steering is at full lock. They must
not become trapped during installation.
• When the steering is at full lock, the handlebar and switch units must not come
into contact with any other components, e.g. the tank or fairing.
• Holes for fastening the switch units must only be drilled through one side of
handlebar. Never drill right through the handlebar.
• Ensure full functionality of the throttle twistgrip unit – it must automatically
spring back into the closed (idle) position when released and must not, for
example, be braked/jammed by the bar ends.

4 | Installation

4.1 | Preparation

Before starting work on your bike, find a suitable place where you can work undisturbed and tidily.
Lay out your tools and the required conversion parts, and jack up the motorcycle securely. Cover the
tank with a cloth to protect it from damage.
Before fitting the new handlebar, use a caliper or similar tool to check that the diameter in the middle
of the handlebar is compatible with the handlebar clamps on your motorcycle. If not, you will need
to use different handlebar clamps that are approved for your motorcycle. Also check that the switch
units will fit on the new handlebar, given its diameter.
Now check that the existing cables are long enough for the new handlebar. The best way to do this
is to ask a friend to hold your original handlebar tightly while you unclamp it from the triple tree.
Then get your helper to hold the handlebar up so that you can measure the cables. Now allow for the
height and width of your new handlebar. If the cables are too short, check if they can be re-routed on
the motorcycle to gain some extra length. Otherwise, you may need to use longer cables.

4.2 | Removal

Once you've done all these checks, you can remove the old handlebar from your bike. The individual
components are easier to remove if you first clamp the handlebar back onto the triple tree.
Then unfasten the bar ends. For this you will definitely need sufficient leverage, as the screw
connection is often stuck tight. It's best to use an impact driver for unscrewing cross-head screws.
If you haven't got an impact driver, give each screw a couple of sharp taps with a hammer and a
screwdriver that fits the screw exactly, and apply a constant force. This should help to loosen the
screw.
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