fat ape and fat mini-ape handlebar and riser kits - Harley
Contents
1. Kit Item Description Quantity Part Number Kit 55857 10 1 Handlebar Fat Ape 16 inch 0 4 M high Satin Black Not sold separately sain BELTED 2 One Piece Fat Handlebar Riser Kit Black 56931 10 Kit 55859 10 1 Handlebar Fat Mini Ape 12 inch 0 3 M high Satin Black Not sold separately ase ae 2 One Piece Fat Handlebar Riser Kit Black 56931 10 Kit 56832 04A 1 Handlebar Fat Mini Ape 12 inch 0 3 M high Chrome Not sold separately Cue 2 One Piece Fat Handlebar Riser Kit Chrome 56929 10 Kit 56942 10 1 Handlebar Fat Ape 16 inch 0 4 M high Chrome Not sold separately Fea 2 One Piece Fat Handlebar Riser Kit Chrome 56929 10 Items common 3 Handlebar grommet large 2 11386 to ALL kits 4 Heat shrink tube large 72162 02 5 Heat shrink tube small 72165 02 Items mentioned in text but not included in kit A Original equipment OE cup washer upper install flat side up 2 B OE bushing 4 C OE spacer 2 D OE cup washer lower install flat side down 2 E OE flat washer 2 F OE split lockwasher 2 G_ OE ground wire H OE internal tooth lockwasher l OE riser mounting screw 2 J Large wire opening 2 J03359 13 of 14 SERVICE PARTS is06360 Figure 10 Service Parts Fat Ape and Fat Mini Ape Handlebar kits is06416 Table 3 Service Parts Twist Grip Sensor Kit 32310 08 Item Description Quant2. 102 mm long piece of heat shrink tubing 4 from the handlebar kit into two equal pieces and slip each piece over a switch wire bundle in the location of the handlebar wire exit hole b Turn signal wires If applicable cut the small 4 inch 102 mm long piece of heat shrink tubing 5 from the handlebar kit into two equal pieces and slip each piece over a turn signal wire in the location of the handlebar wire exit hole If Applicable WARNING Be sure to follow manufacturer s instructions when using the UltraTorch UT 100 or any other radiant heating device Failure to follow manufacturer s instructions can cause a fire which could result in death or serious injury 00335a e Avoid directing heat toward any fuel system com ponent Extreme heat can cause fuel ignition explosion resulting in death or serious injury e Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being performed e Always keep hands away from tool tip area and heat shrink attachment 2 Use a heat gun or suitable radiant heating device to shrink the heat shrink tubing to the wire bundles 3 For models equipped with twist grip sensor see Figure 11 Slip the vinyl conduit tubing 11 over all of the twist grip sensor wires Slip enough tubing up to and overlap ping the point where the wires exit the handlebar Trim excess conduit tubing to expose the sensor terminal pins M 4 R
3. install the fuel tank See the ser vice manual 2 See the service manual and install the headlamp nacelle and headlamp 3 See the service manual to install the headlight into the nacelle 4 Install the windshield if equipped Road King Models 1 If loosened or removed install the fuel tank per instructions in the service manual J03359 2 See Figure 8 To avoid possible damage to the brake line verify that the edge protectors 10 remain installed on the inside edges of the headlamp nacelle 11 Replace the edge protectors if missing cracked or damaged See Figure 9 Loosen the two acorn nuts securing the left half of the nacelle see arrows Repeat for the right half of the nacelle is05766 Figure 9 Headlamp Nacelle Fasteners FLHR Models See Figure 8 Fasten the new handlebar cover 1 to the fork lock 2 mechanism For North America and 2014 and later International models use the two flat head screws 12 removed earlier Tighten the flat head screws to 10 20 in Ibs 1 1 2 3 Nm For 2013 and earlier Australia Brazil England Europe and Japan use two new special screws H D Part No 2935A purchased separately Tighten the screws 12 until the break away heads snap off Press the original fork lock plate 13 into position on the handlebar cover Insert the screw 14 removed earlier through the hole at the front of the handlebar cover and the top of the head lamp nacel
4. 41 54 Nm J03359 is06432 Handlebar cover Fork lock Riser base Handlebar Handlebar riser plane Knurled area 2 Riser clamp Clamp screw 4 Clamp washer 4 10 Edge protector 2 11 Headlamp nacelle 12 Handlebar cover screw 2 13 Fork lock plate 14 Handlebar cover front screw 15 Nut 16 Flat washer 17 Nacelle trim strip 18 Weld stud 2 19 Flange nut 1 2 3 4 5 6 7 8 9 Figure 8 FLHR Ape Handlebar Riser Configuration HAND CONTROL AND SWITCH WIRE HOUSING INSTALLATION 1 For all models EXCEPT 2008 and later Road King Refer to the service manual and follow the instructions to install the new purchased separately throttle control cables and a new purchased separately or OE right grip throttle sleeve assembly For 2008 and later Road King and Freewheeler models Refer to the service manual and follow the instructions to install the new twist grip sensor compatible purchased separately or original right grip throttle sleeve 2 Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort The 9 of 14 brake master cylinder must be horizontally roughly level while the vehicle is on its sidestand 3 Tighten first the top then the bottom brake lever clamp screws to 72 108 in Ibs 8 1 12 2 Nm 4 Tighten first the lower then the upper switch housing screws to 35 45 in Ibs 4 0 5 1 Nm This will leave a
5. clutch lever assemblies from the handlebar along with the attached turn signal lamps and mirrors if equipped 8 Pull the wire sheath and enclosed harnesses through the handlebars to free the handlebar controls and turn signal lamps from the motorcycle Set the handlebar control turn signal lamp assemblies aside 9 Refer to the service manual for removal of the right side switch housing assembly and harness This is necessary to access the throttle cables 10 Refer to the service manual to disconnect the idle and throttle cables from the right grip throttle sleeve assembly Disconnect the idle and throttle cables from the induction module If not being replaced remove the right grip throttle sleeve and set it aside for installation to the new handlebar 11 Refer to the service manual for removal of the left side switch housing assembly and wire harness 12 For all Dyna and Softail models EXCEPT Rocker FXCW C See Figure 1 Remove and discard the screws 1 upper clamp 2 and handlebar 4 For Rocker FXCW C models See Figure 2 Remove and discard the four hex socket head screws 1 that fasten the handlebar upper clamp 2 to the riser 3 Remove and discard the clamp Remove the handlebars 4 and 5 from the motorcycle is00332a Ss 1 Clamp screw 4 2 Clamp 2 on FXSTD 1 on others 3 Handlebar riser 2 4 Handlebar 5 Riser attaching bolt 2 Figure 1 Handlebar C
6. correct connector section in the service manual appendix for disconnection procedures 2012 and later Dyna and 2011 and later Softail models use JAE connectors that do not require depinning to feed through the handlebar 3 Remove and discard any plastic wiring retainer clips and cable straps retaining the handlebar control and turn signal wiring from the handlebars to the harness junction con nectors As needed refer to the correct connector section in the service manual appendix to disconnect the handlebar control wiring from the gray eight way and black six way main harness connectors under the fuel tank NOTE Before disconnecting the turn signal wiring note the turn signal wire routing 4 Separate the six way turn signal connector halves if equipped 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 J03359 leader tight enough to enter the grommet hole and pass easily through the new handlebars 7 Remove the front brake master cylinder and
7. same configuration it was removed earlier b Road King models See Figure 8 Place the handlebar cover 1 oriented as shown over the fork lock 2 c Insert the riser base 3 legs through the holes in the handlebar cover and fasten the riser with the mounting bolts removed earlier Do not fully tighten at this time NOTE ALL models Typical handlebar orientation places the handlebar riser plane 5 parallel to the front forks of the vehicle however state or local regulations may dictate handlebar height limits Research and adjust accordingly 2 Install the handlebar 4 to the riser base routing the wire bundles down through the riser base center hole handlebar cover if equipped and the large oval opening in the upper fork bracket triple tree 3 Seat the handlebar with the knurled areas 6 centered on the riser base Install the riser clamp 7 and clamp fasteners 8 9 per the riser kit instructions but do not fully tighten at this time 4 With the handlebar centered and oriented tighten the riser clamp fasteners to 15 18 ft lbs 20 3 24 4 Nm Tighten the front pair of fasteners first then the rear pair Tighten to the same values a second time to be sure of adequate distribution of the riser clamp loading 5 One at a time remove the riser base mounting bolts apply a few drops of Loctite 271 Red to the 4 6 threads nearest the end and install 6 Tighten the riser base mounting bolts to 30 40 ft lb
8. to reach the vehicle main harness c Connect the six way Multilock pin and socket hous ings d Install any clips and or wire guides saved earlier 10 of 14 5 For all models EXCEPT 2008 and later Road King Proceed to FINAL ASSEMBLY For 2008 2013 Road King models Connect the three way cruise control pin and socket housings within the nacelle per instructions in the service manual 6 Obtain the six way black Molex pin housing 8 from the Twist Grip Sensor components Insert each pin terminal M from the twist grip sensor into the correct cavity of the pin housing as follows From the yellow conduit a BLACK wire to cavity 1 b WHITE wire to cavity 2 c RED wire to cavity 3 From the black conduit a BLACK wire to cavity 4 b WHITE wire to cavity 5 c RED wire to cavity 6 7 Connect the six way black Molex pin housing from the twist grip sensor to the black six way socket housing inside the nacelle Position the previously installed PVC tubing to prevent chafing of the twist grip sensor wires inside the nacelle FINAL 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 Dyna and Softail Models 1 Install the fuel tank per instructions in the service manual Proceed to SAFETY CHECK Freewheeler Models 1 If loosened or removed
9. tug may be necessary to release the index pins in the grip from the receptacle in the seal cap If the throttle grip IS NOT being replaced After removing the grip note if the seal cap is attached to the end of the twist grip sensor If not remove the seal cap from the index pins inside the throttle grip with a stiff piece of mechanics wire For 2013 and earlier models the OE twist grip sensor MUST be replaced with Twist Grip Sensor Kit H D Part No 32310 08 See Table 3 2014 and later models reuse the stock twist grip sensor 13 If required see the service manual to remove and discard the OE twist grip sensor and twist grip sensor jumper harness is00308a Headlamp Handlebar cover Fork lock plate Nacelle left half Nacelle trim strip Wind deflector FLHRS only Nut Flat head screw 2 Pan head screw 10 Flat washer 11 Nut with washer 12 Flange head screw 3 CON OOTP Oye Figure 3 Nacelle Headlamp and Handlebar Cover FLHR Shown J03359 14 For ALL Road King models See Figure 3 Reach inside the headlamp nacelle 4 and remove the flange nut 7 to release the trim strip 5 at the top of the nacelle NOTE Fat ape and fat mini ape handlebars are not compatible with the OE wind deflector 6 on FLHRS models The deflector and trim strip 5 on those models can be discarded and a new trim strip H D Part No 67868 03 available separately must be installed 15 For North Am
10. JAE connectors from the caddies on either side of the steer head 2 on right and 1 on left For vehicles with handlebar mounted turn signals separate the six way turn signal connector halves NOTE Current extended wire switch kits available for cruise control equipped models are limited to 2008 2013 models 8 For 2008 2013 models only Disconnect the electronic cruise control wiring from the two four way connectors if equipped 9 See the service manual and perform the following a Remove the right side switch housing assembly and harness b For 2007 and earlier models Disconnect and remove the throttle idle cables from the currently installed right hand grip throttle sleeve assembly c For ALL models Remove the left side switch housing assembly and wire harness 10 Remove and discard any wire retaining clips attached to the harnesses or the handlebar 11 If the left hand grip is not glued to the handlebar Remove the end cap from the grip if equipped Remove the hand grip and set it aside for installation onto the new handlebar if desired 12 Remove the end cap from the right hand grip if equipped then remove the grip from the handlebar 4 of 14 NOTES On 2008 and later models The twist grip sensor in the right side of the handlebar has a seal cap that protects internal electrodes from dirt and moisture and also acts as a retainer for the right hand throttle grip To remove the throttle grip a slight
11. 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 and is available from a Harley Davidson dealer Kit Contents See Figure 10 Table 2 and Table 3 1 of 14 Please dispose of materials responsibly PREPARATION WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explosion which could result in death or serious injury 00049a ag Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables negative cable first Retain all seat mounting hardware 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 co
12. cMOTOR HARLEY DAVIDSON WY J03359 INSTRUCTIONS REV 2015 06 01 FAT APE AND FAT MINI APE HANDLEBAR AND RISER KITS GENERAL Kit Numbers 55857 10B 55859 10B 56832 04C 56942 10B 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 Table 1 Models Kit Handlebar Description 55857 10B Fat Ape 16 inch 0 4 M high Satin Black 55859 10B Fat Mini Ape 12 inch 0 3 M high Satin Black 56832 04C Fat Mini Ape 12 inch 0 3 M high Chrome 56942 10B Fat Ape 16 inch 0 4 M high Chrome This kit does not fit models equipped with heated hand grips handlebar mounted gauges a Softail Nacelle Kit H D Part No 67907 96 or the Road Tech Radio Additional Parts or Accessories Required This kit includes a handlebar riser assembly that must be installed with this handlebar Separate purchase of additional 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 WARNING 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 brake line gaskets found at each banjo fitting must be r
13. els only Note the wire colors and positions in each cavity of the connector housings leading from the switches Refer to the correct connector section in the service manual appendix Remove the wires with socket ter minals from the socket housings 5 of 14 NEW HANDLEBAR INTERNAL WIRING 1 For Dyna and Softail models Remove any cable straps and plastic wiring retainer clips that secured the switch harnesses to the OE handlebar For 2013 and earlier Road King models Install the Extended Wire Handlebar Switch Kit purchased separ ately into the right side and left side handlebar switch housings per the instructions in that kit For ALL models See Figure 10 Slide one large grommet 3 onto each of the switch wire bundles positioning the grommet close to the switch end 2 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 NOTE Guide strings or thin wires may aid in the routing of the wire bundles through the handlebar For each wire bundle to be routed through the handlebar pre route a separate string through the bar One at a time tape a string securely to the correct wire bundle end Until use secure the remaining guide strings to the handlebar at each end to prevent being pulled through prema turely Pull the string through the bar to route the wire bundle to the proper exit po
14. emove the tape from the ends of the wire bundles 5 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 8 of 14 RISER AND HANDLEBAR INSTALLATION NOTES This kit includes a handlebar riser assembly that must be installed with this handlebar FXCW C models will require the additional purchase of two riser mount fasteners H D Part No 3471 and two split lock washers H D Part No 7068 to replace those removed and discarded earlier see Figure 2 Items 6 and 7 Road King models will require the additional purchase of a handlebar cover to be set in place loosely prior to installation of the riser Covers are available in chrome 2013 and earlier H D Part No 55879 10 2014 and later H D Part No 55800289 or black 2013 and earlier H D Part No 55881 10 2014 and later H D Part No 55800290 to match or contrast with the riser and handlebar In addition FLHRS models will require the purchase of a trim strip H D Part No 67868 03 2013 and earlier Australia Brazil England Europe and Japan models will require the additional purchase of two 10 24 x 1 2 inch tamper proof flat head fasteners H D Part No 2935A 1 ALL models See Figure 10 Install the new handlebar riser per the instructions in the riser kit a Assemble the riser isolation hardware in the
15. eplaced Refer to the parts catalog for this year model motorcycle or see a Harley Davidson dealer for the correct part numbers J03359 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled Motorcycles equipped with a glued left side hand grip will also require a new grip sold separately e Refer to the parts catalog for replacement original equip ment OE hand grips 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 required for the proper installation of this kit Fresh uncontaminated hydraulic brake fluid will also be needed Refer to the owner s manual or service manual for this year model motorcycle to determine the correct brake fluid for this vehicle These items are available from a Harley Davidson dealer ABS Models 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
16. erica and 2014 and later International models Remove and retain the two flat head Phillips screws 8 underneath the label plate that hold the handlebar cover to the fork lock For 2013 and earlier Australia Brazil England Europe and Japan The flat head screws 8 have break away heads and are not easily removable To remove screws with break away heads make a pilot hole in the top of each screw with a center punch and back out the screw with a 1 8 inch 3 mm left hand drill bit If that fails use a 3 16 inch 5 mm long shank drill bit to carefully drill off the heads of the break away screws Use a pliers to remove the screw shafts from the fork lock 16 For ALL Road King models See the service manual and follow the steps to remove and discard the handlebar cover wind deflector and handlebar For Freewheeler models See the service manual and follow the steps to remove and discard the handlebar cover headlamp nacelle and handlebar NOTE Note the sequence and orientation of the riser hardware as it is removed and retain it for later installation Loosely install handlebar and clamps to ease removal of riser mounting bolts 17 Remove the two riser mounting bolts from under the upper fork bracket Remove and discard the handlebar risers but save the hardware for later installation NOTE DO NOT remove the wires from the Molex or Deutsch handlebar switch connector housings inside the nacelle 18 2013 and earlier mod
17. grip ends upward gently feed the right side switch wire bundle into the large opening on the underside of the new handlebar and toward the large opening in the center of the bar AWARNING 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 11 Pull the taped ends of the wire bundle through the exit opening in the center of the handlebar bringing the switch housing into approximate final position DO NOT fasten the switch housing to the handlebar at this time 12 Repeat Steps 9 through 11 with the left side switch wire bundle J03359 isO6366 1 Center wiring hole 2 Upper switch mounting screw 3 Lower switch mounting screw 4 Position inside switch edge pinch point above wires and hole in handlebar 5 Keep wires clear of pinch points near threaded post 6 Large grommet Figure 6 Switch Housing Wire Routing WARNING Grommets in each of the wiring holes in the handlebar must remain in position after routing the wiring through the handlebar Operation without the grommets in place can damage wires causing a short circuit which could result in death or serious injury 00416d 13 For ALL models See Figure 10 Insert the switch wire grommets 3 into place in the switch wire openings in
18. il and 2007 2013 Road King models use Molex connectors 2006 and earlier vehicles use Deutsch connectors Refer to the correct connector section in the service manual appendix for connection procedures 2 As required refer to the notes made during the removal steps and the correct connector section and wiring dia gram in the service manual appendix Insert each terminal from the left side switch wire bundle into the correct cavity of the gray eight way or six way connector housing removed earlier Insert each terminal from the right side switch wire bundle into the correct cavity of the black six way connector housing removed earlier NOTE Switch wire harness extensions purchased separately may be necessary to extend the switch wire harnesses to reach the vehicle main harness 3 Connect the left side handlebar control pin and socket housings Connect the right side handlebar control pin and socket housings 4 For models with handlebar mounted turn signals a Refer to the notes made during the removal steps and the correct connector section and wiring diagram in the service manual appendix Insert each terminal from the turn signals into the correct cavity of the black six way Multilock connector housing removed earlier b Follow the routing noted earlier to the vehicle main harness turn signal connector A turn signal wire harness extension purchased separately may be necessary to extend the turn signal wire harness
19. int Specific instructions for each wire bundle follow 3 For models WITHOUT handlebar mounted turn signals Proceed to Step 9 after Figure 5 For models WITH handlebar mounted turn signals If the original turn signal wires passed through the switch housings and into the handlebar through the large opening J proceed to Step 4 after Figure 4 See Figure 4 If the original turn signal wires were externally routed these turn signals require relocation off the handlebars Relocate at this time following instructions in the appropriate relocation kit 4 Ifthe original turn signal wires passed THROUGH the switch housings Remove the turn signal from the front brake lever assembly mirror stalk and allow to dangle from the switch housing Cover or otherwise protect the turn signal from damage until later installation J03359 is06411a LO BO 1 Turn signal 2 Externally routed turn signal wires Figure 4 Handlebar Mounted Turn Signals Requiring Relocation NOTE See Figure 5 Verify that the large grommet 7 has been positioned on the switch and turn signal wire bundle close to the switch end 5 Apply a light coat of liquid soap window cleaner or all purpose lubricant to the right side turn signal and switch wire bundles 6 With the handlebar placed on a smooth soft surface grip ends upward gently feed the right side switch wire bundle into the large opening on the underside of the new ha
20. ipe up any brake fluid spillage with a clean dry soft cloth Follow up by thoroughly wiping the affected area with a clean damp soft cloth small spills or washing with a large quantity of soapy water large spills 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 3 Drain the brake fluid from the front brake reservoir and brake lines per the instructions in the service manual 2 of 14 ORIGINAL HANDLEBAR REMOVAL NOTE Cover the front fender and the front of the fuel tank with H D Service Covers or clean shop towels to prevent scratching the finish Remove the windshield if equipped Dyna and Softail Models NOTICE Remove brake line components carefully Damage to seating surfaces can cause leakage 00320a 1 Note the front brake line routing and the orientation of the banjo fittings See the service manual to disconnect and remove the brake line Save the banjo bolts but discard the brake line gaskets 2 See the service manual and disconnect the clutch cable from the clutch lever Disconnect the clutch cable from the side cover and remove the cable from the vehicle NOTES Before disconnecting the handlebar contro wiring note the wire routing 2007 2011 Dyna and 2007 2010 Softail models use Molex connectors 2006 and earlier vehicles use Deutsch connectors Refer to the
21. ity Part Number Items for Twist Grip Sensor 7 Sensor twist grip TGS Not sold separately 8 Pin housing six way 72188 07BK 9 Anchor connector T stud 73212 07 10 Cable strap 10006 11 Tubing PVC Not sold separately Figure 11 Service Parts Twist Grip Sensor Kit 32310 08 J03359 Items used with Heated Hand Grips only 12 Socket housing two way 72112 94BK 13 Secondary lock two way 72152 94 socket housing 14 Seal pin plug 2 72195 94 15 Pin housing two way 72102 94BK 16 Secondary lock two way 72142 94 pin housing Items mentioned in text K Heated handgrip wire and socket terminal 2 L Twist grip sensor pin terminal 6 14 of 14
22. l gaskets can cause brake 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 J03359 WARNING When any hydraulic brake component line or connection is loosened or replaced on an ABS motorcycle Digital Technician Il must be used during the brake bleeding procedure to verify all air is removed from the system Failure to properly bleed the brake system could adversely affect braking which could result in death or serious injury 00585c ELECTRICAL RECONNECTION 1 Follow the routing noted in the disassembly steps until the handlebar control wires reach the main vehicle harness switch wire connector housings Dyna and Softail models under the fuel tank left switch wire bundle along the left side of the frame backbone right switch wire bundle along the right side of the backbone Road King and Freewheeler models to inside of head lamp nacelle or aside the frame steer head Install any clips or wire guides saved in disassembly NOTE 2007 2011 Dyna 2007 2010 Softa
23. lamps and Risers Dyna and Softail Models 3 of 14 D ho Wee SY a 1 Clamp screw 4 Handlebar upper clamp Handlebar riser Right side handlebar Left side handlebar Riser mounting bolt 2 Lockwasher 2 ALO OR ON Figure 2 Handlebar Clamp and Riser Rocker Models 13 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 if not being replaced NOTE Note the sequence and orientation of the riser hardware as it is removed and retain it for later installation 14 For all Dyna and Softail models EXCEPT Rocker FXCW C See Figure 1 Remove the two riser mounting bolts 5 from under the upper fork bracket Remove and discard the handlebar risers 3 but save the remaining riser isolation hardware for later installation For Rocker FXCW C models See Figure 2 Remove and discard the two riser mounting bolts 6 and lock washers 7 from under the upper fork bracket Remove and discard the handlebar riser 3 but save the remaining riser isolation hardware for later installation For all Dyna and Softail models Proceed to NEW HANDLEBAR INTERNAL WIRING 2003 and Later Road King Models 2016 and later Freewheeler Models NOTICE Remove brake line components carefully Damage to seating surfaces can cause leakage 00320a 1 Remove and save the button head screw on the underside of the fork stem and bracket asse
24. le 11 Reach inside the nacelle and install the nut 15 and flat washer 16 onto the screw threads Tighten the screw to 10 20 in Ibs 1 1 2 3 Nm Insert the hook of the trim strip 17 into the slot on the handlebar cover Insert the weld studs 18 on the trim strip into the holes at the top of the headlamp nacelle and reach inside the nacelle to install the flange nut 19 Tighten the nut to 15 20 in Ibs 1 7 2 3 Nm See the service manual to install the headlight into the nacelle Install the windshield if equipped 11 of 14 SAFETY CHECK IWAN IN 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 Be sure wires clutch cables throttle idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops NOTE Verify that the ignition key switch is in the OFF position before attaching the battery cables WARNING 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 ps Refer to the service manual and follow the instructions given to attach the battery cables positive cable first Apply a light coat of Harley Davidson electrical contact lubricant H D Part No 99861 02 pe
25. mbly that holds the brake line manifold tee 2 Note the front brake line routing and the orientation of the banjo fittings See the service manual to disconnect and J03359 remove the brake line Save the banjo bolts but discard the brake line gaskets Models with ABS brakes Remove the lines all the way back to the brake controller unit 3 With ALL brake systems See the service manual Dis connect the clutch cable from the clutch lever or the clutch line from the master cylinder Disconnect the clutch cable or line from the side cover 4 Remove the front brake master cylinder and clutch lever assemblies from the handlebar 5 See the service manual and remove the headlamp assembly from the headlamp nacelle NOTES 2007 2013 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 and connection procedures 2014 and later models use JAE connectors that do not require depinning to feed through the handlebar 6 Remove the plastic wiring retainer clips that secure the turn signal harnesses to the handlebar if equipped 7 For 2013 and earlier models refer to the correct connector section in the service manual appendix to disconnect the handlebar control wiring from the gray six way or eight way and black six way main harness connectors inside the headlamp nacelle For 2014 and later models disconnect the
26. ndlebar 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 7 Pull the taped ends of the wire bundle through the exit opening in the center of the handlebar bringing the switch housing into approximate final position DO NOT fasten the switch housing to the handlebar at this time 8 Repeat Steps 4 through 7 with the left side switch wire bundle Proceed to Step 13 NOTE These turn signals require relocation off the handlebars Relocate at this time following instructions in the appropriate relocation kit 6 of 14 isO6366b Center wiring hole Upper switch mounting screw Lower switch mounting screw Position inside switch edge pinch point above wires and hole in handlebar Keep wires clear of pinch points near threaded post 6 Front turn signal ROND o 7 Large grommet Figure 5 Turn Signal and Switch Wire Routing Through Switch Housing 9 Ifthe original turn signal wires were RELOCATED or there are NO handlebar mounted turn signals Apply a light coat of liquid soap window cleaner or all purpose lubricant to the right side switch wire bundle 10 See Figure 6 With the handlebar placed on a smooth soft surface
27. ny gap in the switch housing at the front for best appearance 5 Verify that the right grip throttle sleeve rotates and returns freely and does not bind 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 D 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 N Refer to the service manual to adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort Tighten first the top then the bottom clutch lever clamp screws to 72 108 in Ibs 8 1 12 2 Nm o Tighten first the lower then the upper switch housing screws to 35 45 in Ibs 4 0 5 1 Nm 10 Refer to the service manual and follow the instructions to install a proper length clutch cable purchased separately IWIN NIN 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 IWIN NIN Replace brake line gaskets Re using origina
28. on the end of the handlebar Different sized tabs and slots prevent improper assembly NOTE The twist grip sensor must be fully seated for correct function isO6366a 1 Center wiring hole 2 Upper switch mounting screw 3 Lower switch mounting screw 4 Position inside switch edge pinch point above wires and hole in handlebar 5 Keep wires clear of pinch points near threaded post 6 Twist grip sensor 7 Large grommet Figure 7 Switch Housing and Twist Grip Sensor Wire Routing 2008 and Later Touring WIRE PROTECTION IWIN NIN Wires exiting the bottom center of the handlebar must be protected from wear with heat shrink tubing at the wire exit hole on the handlebar Failure to protect wires with shrink tubing can cause short circuits or severed wires which could cause loss of vehicle control resulting in death or serious injury 00432c J03359 NOTE The heat shrink tubing on the wire bundles exiting the bottom center of the handlebar must be installed to protect the wires from damage and short circuits at the wire exit hole on the handlebar 1 With all harnesses pulled through the handlebar center opening and both handlebar switch housings plus turn signals and twist grip sensor if equipped correctly located and positioned install shrink wrap from the various kits to protect the wires from chafing on the exit hole edges a Handlebar switch harnesses See Figure 10 Cut the large 4 inch
29. the handlebar NOTE A light coat of liquid soap window cleaner or all purpose lub ricant may aid in grommet installation 14 For all models EXCEPT 2008 and later Road King and Freewheeler models Proceed to WIRE PROTECTION NOTES For 2008 2013 Road King models DO NOT use the OE twist grip sensor with the new handlebar The small green connector on the OE sensor is not compatible with internally wired handlebars The OE sensor MUST be replaced with a Twist Grip Sensor Kit H D Part No 32310 08 sold separately See Figure 11 and Table 3 For 2014 and later Road King and Freewheeler models Reuse the stock twist grip sensor with the smaller internal wire bundle This installation is not compatible with heated hand grips so the shorter heated handgrip portion K of the twist grip sensor wiring WILL NOT BE USED in this installation Those wires can be cut short and taped off to avoid interference with the installation or left bundled and taped inside the handlebar 15 Tape the ends L of the longer pair of harness bundles together tight enough to be passed easily through the handlebar 7 of 14 Apply a light coat of liquid soap window cleaner or all purpose lubricant to the twist grip sensor wire bundle 16 See Figure 7 Feed the twist grip sensor wire bundle into the right side handlebar end and toward the large opening in the center of the bar while fitting the index tabs on the twist grip sensor into the slots
30. troleum jelly or cor rosion retardant material to the battery terminals AWARNING Be sure that all lights and switches operate properly before operating motorcycle Low visibility of rider can result in death or serious injury 00316a J03359 2 Turn the ignition key switch to IGNITION but do not start the motorcycle Test each handlebar switch for proper operation 3 Turn the handlebar to the left and right steering stops testing the handlebar control functions at each stop 4 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 WARNING 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 12 of 14 SERVICE PARTS Table 2 Service Parts Fat Ape and Fat Mini Ape Handlebar Kits
31. uld result in death or serious injury 00330a 2 Loosen or remove the fuel tank Refer to the service manual If able to access all harness and throttle cable connec tions the fuel tank may be moved up and rearward without disconnecting the fuel line or crossover If NOT able to access these connections the fuel tank will have to be completely removed and set aside for later installation J03359 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 00239b NOTE Immediately w
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