gazzini 10039168 Street X Real Carbon Handlebar Instructions

: June 6, 2024
: gazzini

Table of Contents

gazzini 10039168 Street X Real Carbon Handlebar
What’s included
General information
Safety
- Risk of injury!
- Risk of damage!
Installation
- Risk of damage!
Storage
Cleaning and care
Warranty
Disposal
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

gazzini 10039168 Street X Real Carbon Handlebar

gazzini-10039168-Street-X-Real-Carbon-Handlebar-pro

What’s included

gazzini-10039168-Street-X-Real-Carbon-Handlebar-pro

General information

Reading and keeping the instructions for use
These instructions for use apply exclusively to the gazzini Real Carbon Handlebar (“handlebar” for short). They contain important information on installation, safety and the warranty. Read these instructions carefully, in particular the safety instructions, before installing the handlebar. Failure to follow the instructions may result in damage to your motorcycle or the handlebar itself. Keep these instructions for future reference. If you pass the handlebar on to a third party, you must also hand over these instructions.
The instructions for use are based on the standards and regulations applicable in the European Union and reflect current state-of-the-art technology. If abroad, you should also observe any country-specific guidelines and laws.

Explanation of symbols
The following symbols and signal words are used in these instructions.

Safety

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.

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.

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.

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.

Installation

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.
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.

You then need to loosen the rubber grips. A professional would blow compressed air between the rubber and the handlebar. At home you can just as well squirt a little dishwashing liquid or brake cleaner (do not use oil, petrol or other fuels) under the grip using a disposable syringe.

Risk of damage!

If the grip is glued to the switch unit or the handlebar, carefully cut it away with a utility knife.
You can then undo and take off the switch units with a suitable cross-head screwdriver.
Remove the brake pump from the handlebar. Always wrap the cables of the brake light switch and the brake pump unit in a cloth and rest them, the right way up, on the light mount, for example.

Do the same with the clutch unit. Now you can completely remove the handlebar from the handlebar clamps. Once the handlebar is detached, it’s easy to remove the throttle twistgrip unit without having to disconnect the throttle cable.
Installation
If the new handlebar has a different clamp diameter, unscrew the existing handlebar clamps from the triple tree and replace them with clamps that are the right fit for your new handlebar. gazzini-10039168-Street-X-Real-Carbon-
Handlebar-3

Next, loosely mount the control units on the new handlebar and align the handlebar to suit your riding style and the lines of the bike. Make sure that the handlebar doesn’t hit the tank or fairing at full lock! Once the handlebar is in its final position, you can tighten the clamps to the torque specified by the manufacturer, but not more than 25 Nm.
If the switch units have locking pins, you will need to drill holes with the diameter of the pins in the handlebar.
First, make absolutely sure that you have found the best installation position for the handlebar and switch units. Also take into account the length of your grips used and the position of the bar ends. Re-check that the switch units do not hit the tank or fairing with the handlebar at full lock, and carefully mark the holes for the locking pins on the handlebar with a marker pen.
Alternatively, you can stick some masking tape around the handlebar and use the switch unit locking pin to make an impression in the masking tape. Masking tape is perfect for making punch-marks to assist drilling. If you’re absolutely certain that you’ve found the best position for your switch units and have correctly marked the drill holes, you can now drill holes with the diameter of the locking pins in one side of the handlebar tube.

gazzini-10039168-Street-X-Real-Carbon-Handlebar-4

The best and safest way to do this is to use a drilling jig (sold separately) for tubular handlebars and a depth stop (to avoid drilling right through the handlebar). Drill the required hole at a relatively low speed. Carefully deburr the hole after drilling.
Now install the switch units, controls, grips and bar ends in their final position, aligning the brake pump and clutch control so that you can operate them with the right amount of force. If the
clutch and brake levers are optimally aligned, your forearm should form a straight line with your outstretched fingers resting on the levers. Check that the throttle twistgrip unit is fully functional – it must automatically spring back into the idle position when released.
Congratulations, you’ve finished converting your handlebar! Check all functions (throttle, clutch, brake, switch units, choke) before setting off for the first time.

Storage

Until you are ready to install the handlebar, keep it in its original packaging and store it in a dark dry place.

Cleaning and care

Clean the handlebar with a mild motorcycle cleaner and clear water, if required.

Warranty

This product comes with the statutory two-year warranty. The warranty period begins on the date of purchase. It does not cover normal wear and tear, use for anything other than the intended purpose, or damage caused by an accident, tampering or attempted repairs by unauthorised persons or customer service departments.