Here are some notes that were posted over on the Yahoo Group, Thanks Curtis:
"Curtis Rock"
I just adjusted my handlebars and considered it a simple 30 minute
process, thanks to the posts here. I adjusted so that the mirror stalks
were about 1/4" from the windshield edge at full rotate positions. Sad thing was that I couldn't get much adjustment out of the position it was at
previously. My knees are about 1 inch from the parking brake on tight turns, with my boots on. I am 6' 0" tall.
For your reference, I sat on my friend's Burgman 650 the other
day, and there is at least 6 inches from the lowest part of his handlebars
to my knees.
Following are a few notes on getting the handlebars to their
highest position. You need a 4mm allen wrench and a 6mm allen wrench. I have the allen wrench kit with rubber handgrip. It provides a nice support for hand torquing and doesn't get in the way, too much, when
removing/installing screws. The 4 mm wrench is for the 4 screws holding the top and bottom handlebar covers together.
As you remove the screws at the handgrip area, note the angle that the screw comes out at, so you know how to quickly align it on the way back in. The angle happens to be exactly 90 deg to the line made by the handgrip part of the handlebar.
Once you get the 4 screws off, unsnap the top and bottom covers
from each other and remove the top cover only.
Use the 6mm allen wrench to break loose the 4 handlebar screws.
While breaking loose, note the level of torque required to loosen them
so you know how to torque them later. For you purists, the service manual says 17 ft-lb torque on these screws.
Slightly loosen, but don't remove, the 4 screws, and the handlebar
will fall to its low position, which is ridiculously low. While keeping the
handlebar horizontally centered in the mounting clamp, turn the wheel to
it's far position and adjust the handlebar rotation so that the mirror
stalk comes close to, but doesn't touch, the windshield. Slightly tighten one of the clamp screws to hold the handlebar in position, and turn the wheel to the far opposite position and check mirror interference.
Note that the screws have an arrow pointing forward (to front of
bike). The arrow must point forward. There is no gap on the front part of
the mount, but there is supposed to be a gap on the back side of the mount. Tighten the front screws to 17 ft-lb., then tighten the back screws
(closest to seat) to 17 ft-lb.
Before snapping the top cover back on, not the alignment of the
bottom cover to the tab on the handlebar at the handgrip area. You will see it requires some pushing of the bottom cover to get the holes aligned. Decide how you need to push the bottom cover when installing that screw later.
Snap the covers together, then install the 4 remaining screws.
The next two steps can be done in any order. Have a beer to
celebrate, and test ride bike.
After my beer, I took a test ride. I noticed a
significant improvement in handlebar height, and eliminated any knee
hitting problems. I did several tight left U-turns in the
neighborhood and had zero problems hitting my knees. This
adjustment was definitely worth it. I think I'll take my allen
wrenches and adjust that Majesty I'm buying in Tulsa before I ride
it down to Dallas this weekend.
Curtis Rock/Dallas TX