Batwing Chizeled Handlebar Instruction Sheet
Contents
1. Knurled pattern 5 of 52. 0239b NOTE If DOT 4 brake fluid contacts painted surfaces IMMEDIATELY flush area with clear water Cover nearby motorcycle surfaces with an H D Service Cover or polyethylene protective sheet to help protect against damage to the finish caused by spillage or splash of DOT 4 brake fluid 2 Refer to the service manual Remove the inner and outer fairing assemblies Do not damage finished surfaces 3 Drain the brake fluid from the front brake reservoir and brake lines per the instructions in the service manual ORIGINAL HANDLEBAR REMOVAL NOTE Cover painted parts to protect finish Remove the windshield if equipped NOTICE Remove brake line components carefully Damage to seating surfaces can cause leakage 00320a Note the front brake line routing and the orientation of the banjo fittings Refer to the service manual Disconnect the brake line Remove the brake line Save the banjo bolts but discard the sealing gaskets N Refer to the service manual and disconnect the clutch cable from the clutch lever Disconnect the clutch cable from the side cover Remove the cable from the vehicle NOTES Record wire routing and cable strap locations before removal J05856 2007 and later models use Molex connectors 2006 and earlier vehicles use Deutsch connectors Refer to the correct con nector section in the service manual appendix for disconnection procedures 3 Remove and discard any plastic wiring retainer c
3. AL ASSEMBLY WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 1 Install the fuel tank per instructions in the service manual SAFETY CHECK WARNING Be sure that steering is smooth and free without interfer ence Interference with steering could result in loss of vehicle control and death or serious injury 00371a e Verify wires clutch line and brake lines do not pull tight when handlebars are turned fully to left or right fork stops Lines must not catch on headlamp hardware or pass in front of headlamp Lines must not catch on turn signal mounting hard ware or turn signals Lines must not catch on fuel cap Lines must not catch on speedometer Make sure that lines are not pinched between the frame and or forks Make sure that clutch line does not pull tight when handlebar is turned fully to left or right fork stops Make sure control wires jumpers do not pull tight when handlebars are turned fully to left or right fork stops NOTE Verify that the ignition switch is in the OFF position before attaching the main fuse 1 Refer to the service manual Install main fuse WARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a 2 Tu
4. cMOTOR HARLEY DAVIDSON WY J05856 INSTRUCTIONS REV 2015 08 14 ACCESSORY HANDLEBAR KIT GENERAL Kit Numbers 55800298 55800299 Models For model fitment information see the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only Installation Requirements Separate purchase of extra parts or accessories are required for proper installation of this handlebar kit See the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only for a list of required parts or accessories for this model IWIN NIN Replace brake line gaskets Re using original gaskets can cause brake failure and loss of vehicle control which could result in death or serious injury 00318a The two sealing gaskets found at each banjo fitting must be replaced Refer to the parts catalog for this year model motorcycle or see a Harley Davidson dealer for the correct part numbers Motorcycles equipped with a glued left side hand grip require a new grip sold separately e Refer to the parts catalog for replacement original equip ment OE hand grips e Refer to the P amp A retail catalog or the Parts and Accessories section of www harley davidson com English only to see the selection of Genuine Motor Accessory hand grips that are available Tools and Supplies Required Loctite 271 Threadlocker and Sealant Red H D Part No 99671 97 is requir
5. e left side switch housing assembly and wire harness 11 If the left side hand grip is not glued to the handlebar Remove the hand grip and set it aside for installation to the new handlebar unless being replaced 12 Refer to the service manual Remove stock handlebar from the handlebar risers Save hardware and riser parts for later installation NEW HANDLEBAR INTERNAL WIRING 1 2014 2015 Models with heated hand grip wiring Cut and remove the unused heated hand grip two pin con nectors from both ends of the harness 2 Unless already done remove any cable straps and plastic wiring retainer clips that secured the switch harnesses to the OE handlebar 3 In not already done use tape to wrap the wire terminal ends from each source to make separate leaders Wrap each leader tight enough to enter the grommet opening and pass easily through the new handlebar 20f5 4 Label each wire bundle left or right to help make sure that wires are routed properly NOTE Guide strings or thin wires aids in the routing of the wire bundles through the handlebar 5 See Figure 1 Stagger the pins 1 so they are not in the same locations along the harness 2 See Figure 2 String a suitable cord 1 through the handlebar Tie the cord to the wire harness Wrap tape 2 over the harness and pins Tape should come to a taper 3 and be flexible to ease pulling through the handlebar Pull the cord through the bar to route the wire bu
6. eaded AO Da post Figure 3 Switch Housing Wire Routing 10 Remove the tape from the ends of the wire bundles 11 Check for electrical continuity between the handlebar and each wire in the wire bundles Continuity would indicate a short circuit which would require examination of the wires and routing in the switch housing HANDLEBAR INSTALLATION NOTE Typical handlebar orientation places the handlebar riser plane parallel to the front forks of the vehicle State or local regula tions may dictate handlebar height limits Research and adjust accordingly 1 See Figure 4 Install the handlebar 1 to the riser base routing the wire bundles down through the upper fork bracket 2 Seat the handlebar with the knurled areas A centered on the riser base Install the riser clamp and clamp bolts but do not fully tighten 3 Adjust handlebar angle The uprights of the handlebar run roughly parallel to the front forks NOTE Tighten the front pair of riser screws first Next tighten the rear riser screws pair 4 With the handlebar centered and oriented tighten the riser clamp fasteners to 12 16 ft lbs 16 3 21 7 Nm HAND CONTROL AND SWITCH WIRE HOUSING INSTALLATION 1 Refer to service manual Install the new purchased sep arately throttle control cables and a new purchased separately or OE right grip throttle sleeve assembly 3 of 5 2 Adjust the position of the switch housing and the brake lever as
7. ed for the proper installation of this kit Fresh uncontaminated hydraulic brake fluid is needed Refer to the owner s manual or service manual for this year model motorcycle to determine the correct brake fluid These items are available from a Harley Davidson dealer ABS Models J05856 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING The rider s safety depends upon the correct installation of this kit Dealer installation is required for vehicles equipped with ABS brakes Proper installation of this kit requires the use of special tools available only through a Harley Davidson Dealer An improperly serviced brake system can adversely affect brake performance which could result in death or serious injury 00578b Non ABS Models WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a NOTE This instruction sheet refers to service manual information A service manual for this year model motorcycle is required for this installation One is available from a Harley Davidson dealer Kit Contents See Figure 4 Table 1 PREPARATION WARNING To prevent accide
8. ke failure and loss of vehicle control which could result in death or serious injury 00318a NOTICE Avoid leakage Be sure gaskets banjo bolt s brake line and caliper bore are clean and undamaged before assembly 00321a 11 Carefully inspect the new brake lines purchased separ ately for damage or defects and replace if damaged Install the brake line per service manual instructions or the instructions included with the brake lines 12 Bleed the brakes per the instructions in the service manual ELECTRICAL RECONNECTION 1 Follow the routing noted in the disassembly steps until the handlebar control wires and turn signal wires reach the main vehicle harness switch and signal wire connector housings NOTE 2007 and later models use Molex connectors 2006 and earlier vehicles use Deutsch connectors Refer to the correct con nector section in the service manual appendix for connection procedures J05856 N Refer to the notes taken during installation Refer to ser vice manual Install the pins into the connector pin hous ings w Install any required electrical extension harnesses sold separately for hand controls and or front turn signal har nesses Refer to the installation instructions for those kits gt Refer to the notes taken during removal and the service manual and connect all harness connectors a See Figure 4 Install hole plugs 2 into the handlebar Make sure to align the logo FIN
9. lips and cable straps retaining the handlebar control and turn signal wiring from the handlebars to the harness junction con nectors Refer to the correct connector section in the service manual appendix to disconnect the handlebar wiring NOTE Before disconnecting the turn signal wiring note the turn signal wire routing 4 Disconnect turn signal connectors NOTES DO NOT remove the wires from the handlebar switch connector housings under the fuel tank DO NOT remove the wires from the Multilock connector housing under the fuel tank 5 Note the wire colors and positions in each cavity of the connector housings leading from the switches and from the turn signals Refer to the correct connector section in the service manual appendix to remove the wires from the housings 6 Use tape to wrap the wire terminal ends from each indi vidual harness to make separate leaders Wrap each leader tight enough to enter the grommet hole and pass easily through the new handlebars 7 Remove the front brake master cylinder and clutch lever assemblies from the handlebar Remove the attached turn signal lamps and mirrors if needed 8 Remove the wire harness from the handlebar Set the handlebar control assemblies aside 9 Remove the twist grip sensor from the handlebar Unless being replaced remove the right grip throttle sleeve and set it aside for installation to the new handlebar 10 Refer to the service manual for removal of th
10. ndle to the proper exit point Zo is08634e 1 Pins 2 Wire harness 3 Two pin heated hand grip harness Figure 1 Pins and Wire Harness AE 1 Pull cord 2 Taped wire harness 3 Tapered end Figure 2 Pull Cord and Wire Harness 6 Apply a light coat of liquid soap window cleaner or all purpose lubricant to the right side switch wire bundle 7 See Figure 3 With the handlebar placed on a smooth soft surface grip ends upward gently feed the right side switch wire bundle into the opening on the underside of the new handlebar and toward the large opening in the center of the bar WARNING Carefully pull the wires through hole in handlebar to pre vent stripping the wires Stripped wires can cause short circuits and damage vehicle electrical components which could cause loss of vehicle control resulting in death or serious injury 00418b 8 Pull the taped ends of the wire bundle through the exit opening in the center of the handlebar Bring the switch housing into approximate final position DO NOT fasten the switch housing to the handlebar now 9 Repeat Steps 4 through 6 with the left side switch wire bundle and both turn signals if needed J05856 is08566 Center wiring hole Upper switch mounting screw Lower switch mounting screw Position inside switch edge pinch point above wires and hole in handlebar 5 Keep wires clear of pinch points near thr
11. ntal vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b WARNING When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00330a 1 Loosen or remove the fuel tank Refer to the service manual 1of5 Please dispose of materials responsibly ACAUTION Direct contact of D O T 5 brake fluid with eyes can cause eye irritation swelling and redness Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 5 brake fluid can cause digestive discomfort If swallowed obtain medical attention Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00144a ACAUTION Direct contact of D O T 4 brake fluid with eyes can cause irritation Avoid eye contact In case of eye contact flush with large amounts of water and get medical attention Swallowing large amounts of D O T 4 brake fluid can cause digestive discomfort If swallowed obtain medical atten tion Use in well ventilated area KEEP OUT OF REACH OF CHILDREN 00240a NOTICE D O T 4 brake fluid will damage painted and body panel surfaces it comes in contact with Always use caution and protect surfaces from spills whenever brake work is per formed Failure to comply can result in cosmetic damage 0
12. rn the ignition switch to IGNITION but do not start the motorcycle Test all switches and lights for proper opera tion 4of5 w Turn the handlebar to the left and right steering stops testing the handlebar control functions at each stop A Apply the front brake hand lever to test operation of the brake lamp WARNING After installing seat pull upward on seat to be sure it is locked in position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070b 5 Refer to the service manual and follow instructions to install the seat WARNING Before starting engine be sure throttle control will snap back to idle position when released A throttle control that prevents engine from automatically returning to idle can lead to loss of control which could result in death or ser ious injury 00390a AWARNING After repairing the brake system test brakes at low speed If brakes are not operating properly testing at high speeds can cause loss of control which could result in death or serious injury 00289a J05856 SERVICE PARTS is08567 Figure 4 Service Parts Chizeled Handlebar Table 1 Service Parts Item Description Quantity Part Number Kit Number 55800298 1 Handlebar chrome Not sold separately Kit Number 55800299 1 Handlebar black Not sold separately Items referenced in text A
13. sembly on the handlebar for rider comfort The brake master cylinder must be horizontally level while the vehicle is on its jiffy stand for brake bleeding 3 Tighten first the top Then tighten the bottom brake lever clamp screws to 60 80 in Ibs 6 7 9 0 Nm 4 Tighten first the lower Then tighten the upper switch housing screws to 35 45 in Ibs 4 0 5 1 Nm This leaves any gap in the switch housing at the front for best appearance 5 Verify that the right grip throttle sleeve rotates and returns freely not binding on the handlebar or switch housing NOTE If the handlebar grips are patterned align the pattern on the left grip with the pattern on the right grip while the throttle is in the fully closed position 6 Install a new purchased separately or OE handlebar grip on the left end of the new handlebar according to the handlebar grip instruction sheet or the service manual 7 Refer to service manual Adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort 8 Tighten first the top Then tighten the bottom clutch lever clamp screws to 60 80 in Ibs 6 7 9 0 Nm 9 Tighten first the lower Then tighten the upper switch housing screws to 35 45 in lbs 4 0 5 1 Nm 10 Refer to the service manual and follow the instructions to install a proper length clutch cable purchased separately WARNING Replace brake line gaskets Re using original gaskets can cause bra
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