multi-fit braided throttle/idle cable kits - Harley
Contents
1. cable 7 5 inch 2 not shown not included in all kits 10006 6 Strap cable 7 8 inch 3 not shown not included in all kits 10073 7 Strap cable 6 0 inch not shown not included in all kits 10065 8 Corrugated tube 2 not shown not included in all kits Not Sold Separately J02811 6 of 62. aller hole of the switch housing located behind the tension adjuster screw 4 Push the throttle and idle control cable housings into the lower switch housing until each snaps into place NOTE For models not equipped with factory installed cruise control if the friction shoe has fallen out or become dislodged install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw 5 Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end Rotate the grip until the ferrule notches are at the top To prevent binding pull the grip back about 0 12 inch 3 2 mm 6 See Figure 3 Position the lower switch housing beneath the throttle control grip Install two brass ferrules Item 3 Figure 11 from this kit onto cables seating the ferrules in their respective notches on the throttle control grip The cables must be captured in the grooves molded into the grip 7 Position the upper switch housing over the handlebar and lower switch housing Route the wire harness conduit through the depression at the bottom of the handlebar J02811 8 Tighten the upper and lower switch housing screws finger tight 9 Position the brake lever master cylinder assembly inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket 10 Align the holes in the handlebar clamp w
3. and idle cables along the right side of the frame backbone After passing through the J clamp on the frame backbone route the cables down to the carburetor induction module w Following completion of cable to Carburetor Induction Module connection procedures insert the tapered end of new 14 inch cable strap between ignition coil and coil bracket welded to underside of frame backbone When cable exits left side raise both ends so that eye is centered above the frame backbone gt A Verify that idle and throttle cables wire bundles wire harness and frame backbone are captured before mating cable strap ends Tighten cable strap but leave loose enough so that one finger can be inserted between strap and frame backbone Do NOT over tighten Cut off excess cable strap material Final Installation IWAN IN Install proper length throttle cables Incorrect cable length can adversely affect motorcycle operation which could cause loss of control resulting in death or serious injury 00396b WARNING Pinched throttle cables can restrict throttle response which could result in loss of control and death or serious injury 00423b Install the carburetor induction module side of the cables Carbureted Models See Figure 4 Install the idle cable housing and spring into the longer cable guide on the carburetor cable bracket Route the idle cable down fit J02811 barrel end into hole in throttle wheel farthest from ca
4. before removing so new straps can be placed into the same locations NOTICE Do not remove or install the master cylinder assembly without first positioning a 5 32 inch 4 mm thick insert between the brake lever and lever bracket Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch 00324a 2 See Figure 1 Place the cardboard insert between the brake lever and lever bracket 3 See Figure 2 Loosen cable adjuster jam nuts Turn cable adjusters in until they are as short as possible This will provide enough slack for easy removal 4 Remove the right upper and lower switch housing screws is00825 _ Brake lever Cardboard 5 32 inch 4 mm 3 Brake lever bracket N Figure 1 Install Cardboard Insert 5 Loosen the upper screw securing the handlebar clamp to the master cylinder housing Remove the lower clamp screw and flat washer NOTE If possible leave the friction shoe in place The friction shoe is a loose fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken 6 See Figure 3 Remove the brass ferrules from the notches on the inboard side of the throttle control grip Remove the ferrules from the cable end fittings 7 Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing For be
5. cMOTOR HARLEY DAVIDSON WY J02811 INSTRUCTIONS REV 2015 05 27 MULTI FIT BRAIDED THROTTLE IDLE CABLE KITS GENERAL Kit Numbers See Table 1 Models For model and fitment information see the P amp A Retail Catalog or the Parts and Accessories section of www harley dav idson com English only NOTE The Multi Fit Throttle Idle Cable Kits are available in a variety of housing lengths fitting angles and travel lengths Shorter or longer lengths may be necessary when modifications i e optional handlebars have been made to the motorcycle See the P amp A Retail Catalog for fitment and length information Additional Parts Required IWAN IN 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 references service manual information A service manual for the specific model motorcycle is required for this installation and is available from a Harley Davidson dealer Kit Contents See Figure 11 and Table 2 REMOVAL IWIN NIN To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Disconnect battery
6. cables negative cable first or remove the main fuse following the instructions in the service manual Table 1 Kit Numbers Model Stainless Steel Kit Diamondback Kit Diamond Black Kit Angle Length in cm Sportster models 2006 and earlier 56564 02 56715 06 N A 45 28 5 72 4 Sportster models 2007 and later N A 56100196 56100197 45 28 5 72 4 Sportster models N A 56726 07 38945 09 45 30 5 77 5 56340 04 N A N A 31 5 80 0 56360 09 38906 07 38913 09 32 5 82 5 56723 04 N A N A 34 5 87 6 N A N A 56100019 25 5 64 8 N A 56100147 56100139 90 27 5 69 9 Softail and Dyna models 56345 03A 56808 05A 38947 09 90 26 5 67 3 55715 07 38781 06 38946 09 28 5 72 4 56344 03A 56807 05A 38954 09 30 5 77 5 56579 02A 56805 05A 38918 09 32 5 82 5 56350 03A 55700 07 38957 09 34 5 87 6 56370 03B 55703 07 55748 10 36 5 92 7 56371 03B 55706 07 55767 10 38 5 97 8 55718 07 55709 07 N A 40 5 102 9 56373 03A 55712 07 N A 42 5 108 0 56720 03 N A N A 70 32 5 82 5 J02811 Please dispose of materials responsibly amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled 1 of 6 NOTE When performing cable disassembly procedures make careful notes as to the existing cable routing Pay special attention to existing cable strap locations
7. ed vertically 2 Cable strap shown prior to trimming ends Figure 10 Cable Routing All Dyna Models 4of6 Softail Models Throttle Idle Cable Routing All Softails Except FLSTS FXSTS and FXSTD Route throttle and idle cables between the brake line and handlebars Pass cables under the top frame tube between the harness con nectors and the harness bracket then to the carburetor induc tion module FLSTS Softail Models Route the throttle and idle cables through the wireform on the right side of the rigid fork under the bottom frame bracket held in place by a cable strap then to carburetor induction module FXSTS Softail Models Route the throttle and idle cables over the handlebars through the wireform on the right side of the rigid fork then into the tunnel area under the fuel tank to car buretor induction module FXSTD Softail Models Route the throttle and idle cables for ward from the throttle control and between the brake line and handlebar riser to the right side of steering head Continue under fuel tank along right side of frame backbone and back to carburetor induction module Touring Models Throttle Idle Cable Routing FLHT FLHTC I and FLTRI Route the cables down following the brake line to the inner fairing Pass the cables through the inner fairing grommet then loop them back along the right side of the steering head e N From the right side of the steering head route the throttle
8. ith those in the master cylinder housing and tighten the lower screw and flat washer finger tight Position for rider comfort Begin ning with the top screw tighten the screws to 60 80 in Ibs 6 8 9 0 Nm NOTE Always tighten the lower switch housing screw first so that any gap between the upper and lower housings is at the front of the switch assembly 11 Tighten the lower and upper switch housing screws to 35 45 in lbs 4 5 Nm is01513 Stop plate Throttle cam stop Throttle wheel Cable barrel end Spring Idle cable guide NO Or Ones Throttle cable guide Figure 4 Throttle Cable Assembly Carbureted Models isO1515 1 Idle cable guide 2 Throttle cable guide Figure 5 Throttle Cable Assembly Fuel Injected Models 3 of 6 is01517 1 Throttle wheel 2 Idle cable barrel end 3 Throttle cable barrel end Figure 6 Throttle Cable Assembly Fuel Injected Models is01518 y 1 Idle cable retaining ring 2 Throttle cable retaining ring 3 Lower switch housing Figure 7 Install Cable to Switch Housing 12 Remove the cardboard insert between the brake lever and lever bracket 13 Refer to the THROTTLE AND IDLE CABLE ROUTING section below Route cables according to the applicable model Sportster Models Throttle Idle Cable Routing Route control cables past left side of right turn signal Loop back through area between headlight and right f
9. les should not catch on speedometer or tachometer Be sure cables are not pinched between the frame and or forks Be sure throttle idle control cables do not pull tight when handlebars are turned fully to left or right fork stops e Cables should return freely from full open to full closed IWIN NIN Connect positive battery cable first If positive cable should contact ground with negative cable connected the resulting sparks can cause a battery explosion which could result in death or serious injury 00068a 6 Connect battery cables positive cable first or install the main fuse if removed 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 7 Turn the ignition light key switch on and apply the brake lever to test operation of the brake lamp 5 of 6 SERVICE PARTS is01521 Sc Se q o D QA ee Figure 11 Service Parts Multi Fit Braided Throttle Idle Cable Kits Table 2 Service Parts Multi Fit Braided Throttle Idle Cable Kits ltem Description Quantity Part Number 1 Cable throttle control braided Not Sold Separately 2 Cable idle control braided Not Sold Separately 3 Ferrule wire control 2 56508 76 4 Clip throttle idle cable 70514 01 5 Strap
10. m stop Install the throttle cable housing into the shorter cable guide inserting barrel end into remaining hole in throttle wheel Fuel Injected Models See Figure 5 and Figure 6 Route the idle control cable around the top of the throttle wheel insert barrel end into upper hole Route the throttle control cable around the bottom of the throttle wheel and insert barrel end into lower hole Using slots slip throttle and idle control cables into cable guides cast at front of induction module 2 Tighten cables as necessary to keep barrel ends from dislodging Verify that cables are seated in channel of throttle wheel Verify operation by turning throttle grip and observing cable action 3 If loosened tighten fuel tank hardware following instruc tions in applicable service manual 4 Install air cleaner assembly following instructions in applicable service manual 5 Adjust throttle and idle cables according to the instructions in the service manual IWIN NIN 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 NOTE Turn the handlebars fully to the left and right stops and check the following items e Cables should not catch on headlamp hardware or pass in front of headlamp Cables should not catch on turn signal mounting hardware or turn signals Cables should not catch on fuel cap or fuel gauge Cab
11. njected Models See Figure 5 Remove idle and throttle control cables from integral cable guides 1 2 cast at front of induction module See Figure 6 Pull cable barrels ends 2 3 from holes in throttle wheel 1 10 Cut and discard cable straps securing cables to frame backbone If present cut cable strap securing cable to coil bracket Remove cables 11 For FL models Release the cables from the J clamp fastened to the right side of the frame backbone If present remove bolt washer P clamp and locknut to release cables from the steering head For Dyna Models Remove existing cable straps from holes in the frame Make sure when routing replacement cables to use the same holes provided for the cable straps 2of6 is02072 Idle cable Brass ferrule Notch Figure 3 Throttle Idle Control Cables INSTALLATION Throttle and Idle Cable Installation 1 See Figure 3 Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable For assembly apply a drop of light oil on the retaining rings of the crimped inserts 2 See Figure 7 Push the throttle cable housing and retaining ring into the larger hole of the switch housing located in front of the tension adjuster screw 3 Push the idle cable housing and retaining ring into the sm
12. ork tube Route rearward under gas tank and secure at clip under ignition switch then down to carburetor induction module Dyna Models Throitle Idle Cable Routing 1 1996 2005 FXD FXDL FXDX FXDS Models See Figure 8 Route throttle and idle cables between headlamp and right front fork tube then under right side of tank to carbur etor induction module 1996 2005 FXDWG Models See Figure 9 Route throttle and idle cables behind the front fork upper bracket then under right side of tank to carburetor induction module 1996 2005 FXDXT Models Route throttle and idle cables through wire form mounted to upper fork bracket then under right side of tank to carburetor 2006 Later FXDi FXDCi FXDBi FXD35 FXDWGi See Figure 9 Route throttle and idle cables behind the front fork upper bracket then under the right side of tank to the induction module 2 All Models See Figure 10 Orient the cable straps as shown with the cable strap loop oriented downward Stack the cables vertically as shown and tighten the cable straps J02811 is01519 1 Throttle idle cables 2 Headlamp 3 Right front fork tube 4 Fuel tank Figure 8 Cable Routing 1996 2005 Dyna Except FXDWG is01520 1 Throttle idle cables 2 Front fork upper bracket 3 Fuel tank Figure 9 Cable Routing 1996 2005 FXDWG 2006 and Later Dyna Models a is01536 A gt i SS RS Le a 1 Throttle idle cables stack
13. st results use a rocking motion while pulling Remove cables with retaining rings from switch housing Apply a drop of light oil on the retaining ring if necessary to help in removal J02811 is02071 GA SIG Upper switch housing Lower switch housing Throttle cable adjuster Idle cable adjuster Adjuster jam nut SO NS Figure 2 Handlebar Throttle Control NOTE If you have or are installing different handlebars measure the change in distance that will be required from the end of the cable housing to the throttle grip Compare this additional required length to the cables provided in your kit If the cables are more than 2 0 inches 51 mm longer or more than 1 0 inch 25 mm shorter than the above measured dis tance see a Harley Davidson dealer for the correct cable length WARNING Install proper length throttle cables Incorrect cable length can adversely affect motorcycle operation which could cause loss of control resulting in death or serious injury 00396b 8 Remove air cleaner assembly following instructions in the applicable service manual NOTE Raise fuel tank to access cables in area of frame backbone if necessary See the service manual 9 Remove cables at Carburetor Induction Module as follows Carbureted Models See Figure 4 Remove cable barrel ends from holes in throttle wheel and release cable hous ings from cable guides on carburetor cable bracket Fuel I
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