Street Slammer Handlebar Kit Instruction Sheet - Harley
Contents
1. 5 Obtain three pieces of string each of approximately 3 5 ft 1 M long a Tie a small weight for example a spare nut or washer small enough to fit through the center wire slot to one end of each string b Place the new handlebar on a horizontal surface so that the riser ends face upward c Insert the weighted end of two of the strings into the right side riser wiring hole and tip the handlebar so that the weights slide out the right grip end of the handlebar If necessary an air hose can be used to blow the weights and strings through the handlebar to the grip end of the bar d While verifying that the non weighted ends of the strings remain extended out of the riser hole pull the weighted ends out of the right grip end of the handlebar Remove the weights from the strings e With a tweezers or similar tool fish one string out through the switch wiring slot near the right side handlebar end Allow the second string to remain extended out of the right side handlebar end f Repeat Steps 3b through 3e with the one remaining string and the left side handlebar end Fish the string out through the switch wiring slot near the left side handlebar end NOTE The handlebar cover on FLHR models must be placed on the handlebar before the wires are installed through the riser wiring holes 6 Slide anew handlebar cover purchased separately onto the handlebar Verify that the strings installed earlier remain extended2. 7 8 9 Figure 2 Nacelle Headlamp and Handlebar Cover FLHR Shown 8 See the service manual and follow the applicable steps to remove the handlebar cover wind deflector and handlebar 9 If the left hand grip is not glued to the handlebar Remove the hand grip and set it aside for installation to the new handlebar if desired NOTE Note the sequence of the riser hardware for correct installation of new risers 10 Remove and discard the stock handlebar risers Save the hardware for installation NOTES 2007 and later models use Molex connectors 2006 and earlier vehicles use Deutsch connectors See the service manual for terminal removal and installation procedures DO NOT remove the wires connector pin housings inside the nacelle 11 Note the wire colors and positions in each cavity of the socket housings leading from the switches and from the 3 of 14 turn signals See the service manual and remove the wires from the socket housings 12 Use tape to wrap the wire terminal ends from each source to make separate leaders Wrap each leader tightly enough to enter the grommet hole and pass easily through the new handlebar Proceed to INSTALLATION is00328 i Ms G WV rd x om a l da On Clamp screw 4 Flat washer 4 Upper clamp 2 Handlebar Handlebar riser 2 Riser mounting screw 2 OaPenna Figure 3 Handlebar Clamps and Risers FLHR Shown H
3. Tighten the lower switch housing screw before tightening the upper screw This will leave any gap in the switch housing at the front for best appearance 12 Tighten the lower then the upper switch housing screws to 35 45 in Ibs 4 0 5 1 Nm 13 Verify that the right hand grip throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing NOTE If the hand grips are patterned align the pattern on the left hand grip with the pattern on the right hand grip while the throttle is in the fully closed position 14 Install a new purchased separately or original hand grip on the left end of the new handlebar according to the hand grip instruction sheet or the appropriate service manual 15 See the service manual and adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort and posture 16 Tighten the top then the bottom clutch lever clamp screws to 71 80 in Ibs 8 0 9 0 Nm 17 Tighten the lower then the upper switch housing screws to 35 45 in Ibs 4 0 5 1 Nm New Handlebar Wiring 2008 and Later Touring Models NOTE The handlebar cover on FLHR models must be placed on the handlebar risers before the wires are installed through the riser wiring holes 1 Slide anew handlebar cover purchased separately onto the handlebar risers Check that the strings installed earlier remain extended out of the riser wiring holes on the underside of the
4. Handlebar Clamps and Risers Dyna and Softail Models 9 If the left hand grip is not glued to the handlebar Remove the hand grip and set it aside for installation to the new handlebar if desired NOTE Note the sequence of the riser mounting hardware for correct installation 10 Remove and discard stock handlebar risers Save hard ware for installation as necessary 2of14 NOTES DO NOT remove the wires from the connector pin housings under the fuel tank 11 Note the wire colors and positions in each cavity of the socket housings leading from the switches and from the turn signals See the service manual and remove the wires from the socket housings 12 Use tape to wrap the wire terminal ends from each source to make separate leaders Wrap each leader tightly enough to enter the grommet hole and pass easily through the new handlebar Proceed to INSTALLATION Handlebar Removal 2007 and Earlier Touring Models NOTE Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching CAUTION 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 and disconnect and remove the brake line Save the banjo bolts but discard the brake line gaskets 2 Remove the plastic wiring retainer clips that secure the turn signal harnesses to the handleb
5. out of the riser holes on the underside of the cover 7 Apply a light coat of liquid soap window cleaner or all purpose lubricant to the right side switch and turn signal wire bundles if equipped J04406 is02823 Wind deflector Wind deflector adapter Flanged screw 3 Handlebar cover Flanged screw 2 Flanged nut 2 DOr Ns Figure 6 Handlebar Cover Wind Deflector Assembly FLHRS 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 bundles through the wire exit hole near the bottom of the right side riser 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 9 See Figure 11 Slide a grommet 2 onto both of the wire bundles sticking out of the riser wire hole and insert the grommet into the riser hole in the handlebar 10 Tie the end of the string from the left side switch wire hole to the left side switch wire bundle 11 If necessary apply a light coat of liquid soap window cleaner or all purpose lubricant to the left side
6. the left side switch wire hole Pull the bundle down through the new handlebar and toward the center of the bar NOTE Insert the right side grommet into the handlebar slot with the flange toward the center of the bar 11 See Figure 11 Insert the switch wire grommets 2 into place in the switch wire holes in the handlebar 12 Loosely fasten the brake lever and clutch lever clamps to the new handlebar J04406 13 Loosely fasten the handlebar switch housings to the new handlebar 14 Remove the tape from the ends of the harnesses 15 Check for electrical continuity between the handlebar and each wire in the harnesses Continuity indicates a short circuit which requires examination of the wires and routing in the switch housing New Handlebar Installation 2008 and Later Touring Models NOTE See the service manual for disconnection and connection procedures 1 Insert each socket terminal from the right side switch har ness into the correct cavity of the black socket housing removed earlier 2 Connect the gray socket housing to the gray eight way pin housing inside the nacelle Connect the black socket housing to the black six way pin housing inside the nacelle If equipped connect the three way cruise control pin and socket housings in the same manner 3 Obtain the PVC tubing from the Twist Grip Sensor Kit purchased separately Install the tubing over ALL of the wires coming from the twist grip sensor
7. with handlebar mounted turn signals slide one small grommet 3 onto each of the turn signal wire bundles positioning the grommet close to the turn signal end NOTE DO NOT use the stock twist grip sensor with the new handlebar The small green connector on the stock sensor is not compatible with internally wired handlebars The stock sensor MUST be replaced with Twist Grip Sensor Kit 32310 08 See Figure 10 4 Use tape to wrap the wire terminals on the ends of the twist grip sensor wires to make a single leader Wrap the leader tightly enough to pass easily through the new handlebar 5 Tie the end of the string from the right side handlebar end hole to the twist grip sensor harness 6 Tie the end of the string from the right side switch wire hole to the right side switch harness WARNING Wiring in the switch housings must be routed exactly as shown Pinch points in the switch housings can short circuit or sever wires which could cause loss of control resulting in death or serious injury 00415b NOTE Apply a light coat of liquid soap window cleaner or all purpose lubricant to harnesses before feeding the harnesses into the handlebar 7 Gently feed the twist grip sensor harness into the right side handlebar end See Figure 8 Route the right side switch wire bundle through the switch housing as shown Gently feed the harness into the right side switch wire hole Pull the bundles down through the new handlebar an
8. 4 Obtain the six way black Molex pin housing from the Twist Grip Sensor Kit purchased separately Insert each pin terminal 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 5 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 CAUTION Improperly aligned handlebars can contact the fuel tank when turned to the left or right Contact with the fuel tank can cause cosmetic damage 00372a 6 Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank If contact occurs and the handlebars are properly centered raise the handlebar angle as necessary until proper clearance is attained 7 One at a time remove the riser bolts Apply a small amount of Loctite 271 Red to the bolt threads and install Tighten the riser bolts to 30 40 ft lbs 41 54 Nm 9 of 14 8 Install a new purchased separately or original hand grip on the left end of the new handlebar according to the hand grip instruction sheet or an appropriate serv
9. England Europe and Japan Tighten the special screws until the break away heads snap off Press the original fork lock plate into position on the handlebar cover Insert the hook of the trim strip into the slot on the handlebar cover Insert the weld stud on the trim strip into the hole at the top of the headlamp nacelle and reach inside the nacelle to install the flange nut Tighten the nut to 15 20 in Ibs 1 7 2 3 Nm See the service manual and install the headlight into the nacelle J04406 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 CAUTION Avoid leakage Be sure gaskets banjo bolt s brake line and caliper bore are clean and undamaged before assembly 00321a 7 o w Carefully inspect the new brake line or lines sold separ ately for damage or defects and replace if damaged Install per the instructions included with the brake lines See the service manual and bleed the brakes See the service manual and install the clutch cable to the clutch lever or install a new clutch cable sold separately 11 of 14 SAFETY CHECK 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 e Be sure wires clutch cables throttle idle cables and brake lines do
10. Twist Grip Sensor Kit 32310 08 Item Description Quantity Items for Twist Grip Sensor 1 Sensor twist grip for internally wired handlebars 2 Pin housing six way 3 Retainer T stud 4 Cable strap 5 PVC tubing Items used with Heated Hand Grips only 6 Socket housing two way 7 Secondary lock two way socket housing 8 Seal pin plug 2 9 Pin housing two way 10 Secondary lock two way pin housing J04406 13 of 14 is00334b Figure 11 Service Parts Table 2 Service Parts ltem Description Quantity Part Number 1 Handlebar Street Slammer Not Sold Separately 2 Handlebar grommet large 2 11386 3 Handlebar grommet small 2 for handlebar mounted turn signals only 11398 J04406 14 of 14
11. andlebar Removal 2008 and Later Touring Models NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching CAUTION 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 assembly 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 and disconnect and remove the brake line Save the banjo bolts but discard the brake line gaskets 3 Remove the front brake master cylinder and clutch lever assemblies from the handlebar 4 See the service manual and disconnect the clutch cable from the clutch lever If the clutch cable is being replaced Disconnect the clutch cable from the side cover and remove the cable from the vehicle J04406 5 See the service manual and remove the headlamp assembly from the headlamp nacelle 6 See the service manual and disconnect the handlebar control wiring from the gray eight way and black six way main harness connectors inside the headlamp nacelle Disconnect the electronic cruise control wiring from the two three way connectors if equipped 7 See the service manual and perform the following a Remove the right side switch housing assembly and harness b Remove the left side switch housing assembly and wire harness 8 Remove and dis
12. ar if equipped 3 Remove the front brake master cylinder and clutch lever assemblies from the handlebar 4 See the service manual and disconnect the clutch cable from the clutch lever If the clutch cable is being replaced Disconnect the clutch cable from the side cover and remove the cable from the vehicle 5 See the service manual and remove the headlamp assembly from the headlamp nacelle NOTE 2007 and later models use Molex connectors 2006 and earlier vehicles use Deutsch connectors See the service manual for disconnection and connection procedures 6 Disconnect the handlebar control wiring from the gray and black 6 way main harness connectors inside the headlamp nacelle Separate the 6 way turn signal connector halves Disconnect the electronic cruise control wiring from the two 4 way connectors if equipped 7 See the service manual and perform the following a Remove the right side switch housing assembly and harness This is necessary to access the throttle idle cables b Disconnect the throttle idle cables from the existing right grip throttle sleeve assembly c Remove the left side switch housing assembly and wire harness J04406 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 1 2 3 4 5 6
13. cMOTOR HARLEY DAVIDSON WY J04406 INSTRUCTIONS REV 2008 08 07 STREET SLAMMER HANDLEBAR KIT GENERAL Kit Number 55975 08A 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 This kit does not fit models equipped with Hydraulic Clutch Kits handlebar mounted gauges or the Road Tech Radio or FLHRS models equipped with an accessory windshield ABS Models 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 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 Additional Parts or Accessories Required Separate purchase of additional parts or accessories is required for proper installation of this Handlebar Kit on your model motorcycle Please see the P amp A Re
14. card wire retaining clips attached to har nesses or the handlebar 9 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 10 Remove the end cap from the existing right hand grip if equipped then remove the grip from the handlebar NOTES 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 throttle grip To remove the hand grip a slight tug may be necessary to release the index pins in the hand 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 The stock twist grip sensor MUST be replaced with Twist Grip Sensor Kit 32310 08 See Figure 10 11 See the service manual and remove the stock twist grip sensor and twist grip sensor jumper harness Save the jumper harness for later installation 12 See Figure 5 Reach inside the headlamp nacelle 5 remove the flange nut 7 to release the trim strip 6 at the top of the nacelle NOTE For Australia Brazil England Europe and Japan See Figure 5 The flat head screws 8 have break away head
15. causing rear lighting failure or other serious electrical problems 4 Turn the handlebar to the left and right steering stops testing the handlebar control functions at each stop 5 Apply the front brake hand lever to test operation of the brake lamp 6 Verify that the throttle operates properly 7 Refer to the service manual and follow instructions to install the seat 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 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 WARNING Be sure headlamp tail and stop lamp and turn signals are operating properly before riding Poor visibility of rider to other motorists can result in death or serious injury 00478b 8 Test tail lamps for proper operation 12 of 14 SERVICE PARTS is05688 Figure 10 Service Parts Twist Grip Sensor Kit 32310 08 Table 1 Service Parts
16. cover 2 Obtain three pieces of string mechanic s wire or equi valent each of sufficient length to extend inside the handlebar from the end of the bar to the lower center wire slot plus 6 12 in 15 30 cm of additional length to extend beyond the openings a Tie a small weight for example a spare nut or washer small enough to fit through the center wire slot to one end of each string b Insert the weighted end of two of the strings into the right side handlebar end and tip the handlebar so that the weights and strings slide down the handlebar to the lower center wire slot J04406 If necessary an air hose can be used to blow the weights and strings through the handlebar to the center slot c While verifying that the non weighted ends of the strings remain extended out of the right side handlebar end pull the weighted ends out of the lower center wire slot Remove the weights from the strings d With a tweezers or similar tool fish one string out through the switch wiring slot near the right side handlebar end Allow the second string to remain extended out of the right side handlebar end e Repeat Steps 1b through 1d with the remaining string and the left side handlebar end Fish the string out through the switch wiring slot near the left side handlebar end 3 See Figure 11 Slide the grommets 2 flange end first onto the switch harnesses positioning the grommet close to the switch end For models
17. d toward the center of the bar while fitting the index tabs on the twist grip sensor into the slots on the end of the 8 of 14 handlebar One index tab and slot are smaller than the other for ease of assembly is00336a 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 Figure 8 Switch Housing and Twist Grip Sensor Wire Routing 2008 and Later Touring 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 harnesses through the center hole of the handlebar 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 9 Tie the end of the string from the left side switch wire hole to the left side switch harness 10 Route the left side switch harness through the switch housing similar to that shown in for the right side wiring Feed the harness into
18. ebar cover Handlebar cover insert Fork lock plate Nacelle left half Nacelle trim strip Nut Flat head screw 2 Pan head screw 10 Flat washer 11 Nut with washer OHONAARYNS Figure 5 Nacelle Headlamp and Handlebar Cover FLHR C Shown INSTALLATION New Handlebar Wiring Dyna Softail 2007 and Earlier Touring Models 1 For models with handlebar mounted turn signals See Figure 11 Slide one small grommet 3 onto each of the turn signal wire bundles positioning the grommet close to the turn signal end 2 Apply a light coat of liquid soap window cleaner or all purpose lubricant to the right side switch wire bundle and turn signal wire bundle if equipped NOTE The handlebar cover on FLHR models must be placed on the handlebar before the wires are installed through the riser wiring holes 3 For FLHR and FLHRC models slide a new handlebar cover purchased separately onto the handlebar 5 of 14 4 For FLHRS models see Figure 6 a Assemble the saved wind deflector 1 to the new adapter 2 purchased separately using the three flanged screws 3 removed earlier b Tighten the screws to 12 18 ft lbs 16 3 24 Nm c Assemble the new handlebar cover 4 purchased separately to the adapter using the two flanged screws 5 and flanged nuts 6 from the adapter kit d Tighten the screws to 12 18 ft lbs 16 3 24 Nm e Slide the handlebar cover wind deflector assembly onto the handlebar
19. ector and three hex head serrated flange screws removed earlier Fasten the cover to the wind deflector with the screws and alternately tighten to 12 18 ft lbs 16 3 24 4 Nm b Position the deflector and cover assembly onto the flange at the top of the headlamp nacelle c Loosely assemble the pan head screw flange nut and flat washer removed earlier d See Figure 9 Holding the screw assembly reach inside the headlamp nacelle and insert just the screw head up through the opening to engage the slot in the tab at the front of the wind deflector The nut and flat washer should remain inside the nacelle Tighten the screw to 10 20 in Ibs 1 1 2 3 Nm Models without wind deflectors a Position a new cover onto the flange at the top of the headlamp nacelle b Insert the screw through the hole at the front of the handlebar cover and the top of the headlamp nacelle Reach inside the nacelle and install the nut and flat washer onto the screw threads Tighten the screw to 10 20 in Ibs 1 1 2 3 Nm NOTE For North America Install new handlebar cover using two flat head screws removed earlier 10 of 14 For Australia Brazil England Europe and Japan Install new handlebar cover using two new screws 2935A purchased separately 3 Install the two screws to secure the handlebar clamp cover to the fork lock mechanism For North America Tighten the flat head screws to 10 20 in Ibs 1 1 2 3 Nm For Australia Brazil
20. ice manual 9 Adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort 10 Tighten the top then the bottom clutch lever clamp screws to 72 108 in Ibs 8 1 12 2 Nm 11 Tighten the lower then the upper switch housing screws to 35 45 in Ibs 4 0 5 1 Nm NOTE If the hand grips are patterned align the pattern on the right hand grip with the pattern on the left hand grip while the throttle is in the fully closed position 12 Refer the appropriate service manual and follow the instructions given to install the new purchased separately or original right hand grip throttle sleeve 13 Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort The brake master cylinder must be level NOTE Tighten the top brake lever clamp screw before tightening the bottom screw 14 Tighten the top then the bottom brake lever clamp screws to 72 108 in lbs 8 1 12 2 Nm NOTE Tighten the lower switch housing screw before tightening the upper screw This will leave any gap in the switch housing at the front for best appearance 15 Tighten the lower then the upper switch housing screws to 35 45 in Ibs 4 0 5 1 Nm 16 Verify that the right hand grip throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing FINAL ASSEMBLY Softail and Dyna Models WARNING Replace brake line gaskets Re using orig
21. inal gaskets can cause brake failure and loss of vehicle control which could result in death or serious injury 00318a CAUTION Avoid leakage Be sure gaskets banjo bolt s brake line and caliper bore are clean and undamaged before assembly 00321a Carefully inspect the new brake line for damage or defects and replace if damaged Install the brake line per the ser vice manual instructions or the instructions included with the Brake Line Kit N See the service manual and bleed the brakes w See the service manual and install the clutch cable to the clutch lever or install a new clutch cable sold separately J04406 Touring 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 1 To avoid possible damage to the brake hose verify that the trim strips remain installed on the inside edges of the headlamp nacelle Replace the strips if missing cracked or damaged is03100 Figure 9 Wind Deflector Assembly to Nacelle FLHRS Models 2 Models with wind deflectors a Obtain the new handlebar clamp cover sold separ ately and the wind defl
22. ine gaskets 2 Remove the plastic wiring retainer clips that secure the turn signal harnesses to the handlebar if equipped 3 Remove the front brake master cylinder and clutch lever assemblies from the handlebar J04406 4 See the service manual and disconnect the clutch cable from the clutch lever If the clutch cable is being replaced disconnect the clutch cable from the side cover and remove the cable from the vehicle NOTE 2007 and later models use Molex connectors 2006 and earlier vehicles use Deutsch connectors See the service manual for disconnection and connection procedures Note wire routing before disconnecting the handlebar wiring 5 Disconnect the handlebar control wiring from the gray and black 6 way main harness connectors under the fuel tank 6 Separate the 6 way turn signal connector halves 7 See the service manual and perform the following a Remove the right side switch housing assembly and harness to access the throttle idle cables b Disconnect the throttle idle cables from the existing right hand grip throttle sleeve assembly or remove them if replacing with new cables c Remove the left side switch housing assembly and wire harness 8 See Figure 1 Remove and discard screws 1 upper clamp 2 and handlebar 4 ko gt x Clamp screw 4 Clamp 2 on FXSTD 1 on others Handlebar riser 2 Handlebar RON T 5 Riser attaching screw 2 Figure 1
23. irect 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 CAUTION 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 NOTES Immediately wipe up any brake fluid spills with a clean dry soft cloth Follow up by thoroughly wiping 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 a polyethylene pro tective sheet to help protect against damage to finish caused by spilled DOT 4 brake fluid 3 See the service manual and drain the brake fluid from the front brake reservoir and brake lines Handlebar Removal Dyna and Softail NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching Damage to the finish could result e Note the front brake line routing and the orientation of the banjo fittings See the service manual and disconnect and remove the brake line Save the banjo bolts but discard the brake l
24. not pull tight when handlebars are turned fully to left or right fork stops 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 1 Verify that the ignition light key switch is turned to the OFF position See the service manual and connect the battery cables or install the 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 Turn the ignition light key switch to IGNITION and test each handlebar switch for proper operation 3 For 2005 and earlier FXDL and FXDWG models AWARNING Be sure plug in lower forward section of rear fender is installed Operation without plug installed could allow tire contact with wiring harness Tire contact with wiring har ness can cause wire damage which could result in death or serious injury 00456b Inspect the lower forward section of the fender inside the rear wheel well A 3 in 76 mm square hole in the fender should be covered with a rubber plug If the plug is damaged loose or missing it MUST be replaced 59150 90 available from a Harley Davidson J04406 dealer Without this plug in place the wire harness could come out of the opening and contact the rear tire
25. 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 6 Dyna and Softail models See the service manual and secure the fuel tank to the frame CAUTION Improperly aligned handlebars can contact the fuel tank when turned to the left or right Contact with the fuel tank can cause cosmetic damage 00372a 7 Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank If contact occurs and the handlebars are properly centered raise the handlebar angle as necessary until proper clearance is attained 8 Remove the riser bolts one at a time Apply a small amount of Loctite 271 Red to the bolt threads and install again See the service manual and tighten the riser bolts to spe cification 9 See the service manual and follow the instructions given to install the throttle control cables and a new purchased separately or original right hand grip throttle sleeve assembly 10 Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort and posture The brake master cylinder must be horizontally level NOTE Tighten the top brake lever clamp screw before tightening the bottom screw 7 of 14 11 Tighten the top then the bottom brake lever clamp screws to 71 80 in Ibs 8 0 9 0 Nm NOTE
26. paration All Models WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 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 1 See the service manual and remove the seat and discon nect battery cables or remove the main fuse Save the seat hardware for installation 1 of 14 IWIN NIN 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 2 Softail and Dyna models See the service manual and loosen the fuel tank 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 D
27. s 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 in 3 mm left hand drill bit If that fails use a 3 16 inch 5 mm long shank drill bit to care fully drill off the heads of the break away screws Use a pliers to remove the screw shafts from the fork lock 13 See the service manual and follow the applicable steps to remove the handlebar cover windshield and handlebar NOTE Note the sequence of the riser mounting hardware for correct installation 4 of 14 14 Remove and discard the stock handlebar risers Save the hardware for installation NOTE DO NOT remove the wires from the Molex handlebar switch connector pin housings inside the nacelle 15 Note the wire colors and positions in each cavity of the socket housings leading from the switches Refer to the appropriate service manual Remove the wires with socket terminals from the socket housings 16 Use tape to wrap the wire terminal ends from each source to make separate leaders Wrap each leader tightly enough to enter the grommet hole and pass easily through the new handlebar Proceed to INSTALLATION is00328a Q Mn cS Clamp screw 4 Upper clamp Handlebar Handlebar riser 2 Riser attaching screw 2 OPena Figure 4 Handlebar Clamp and Risers FLHR Shown J04406 is02829a Headlamp Handl
28. switch wire bundle 12 Route the left side switch wire bundle through the switch housing similar to that shown in Figure 6 for the right side wiring Gently feed the wire bundle into the left side switch wire hole 6 of 14 Pull the bundle down through the new handlebar and out through the wire exit hole near the bottom of the left side riser 13 Loosely fasten the brake lever and clutch lever clamps to the new handlebar 14 Loosely fasten the handlebar switch housings to the new handlebar 15 Remove the tape from the ends of the wire bundles 16 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 is00336 alaia N del 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 threaded post PONS Figure 7 Switch Housing Wire Routing Dyna Softail and 2007 Earlier Touring New Handlebar Installation Dyna Softail 2007 and Earlier Touring Models 1 Dyna and Softail models a Route the switch harnesses down through the large oval opening in the upper fork bracket then route them to the switch connectors under the fuel tank as previously noted b Route both turn signal harnesses down
29. tail Catalog or the Parts and Accessories section of www harley davidson com English only for a list of required parts or accessories for your model For Australia Brazil England Europe and Japan two special screws 2935A will also be required Tools and Supplies Required Loctite 271 Red Threadlocker and Sealant 99671 97 is required for the proper installation of this kit Fresh uncontaminated brake fluid from a sealed container will also be needed Refer to the owner s manual for the appropriate brake fluid J04406 IWAN IN 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 For models that re use the original brake line the two brake line gaskets found at each banjo fitting must be replaced Refer to the appropriate Parts Catalog or see a Harley Dav idson dealer for the correct part numbers Motorcycles equipped with a glued left hand grip will also require a new grip sold separately Refer to the Parts Catalog for replacement stock hand grips Ask a Harley Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available NOTE This instruction sheet references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Kit Contents See Figure 11 and Table 2 REMOVAL Pre
30. through the large oval opening in the upper fork bracket then route them to the 6 way turn signal pin housing under the right side of the fuel tank as previously noted NOTE 2007 and later models use Molex connectors 2006 and earlier vehicles use Deutsch connectors See the service manual for disconnection and connection procedures J04406 N Refer to the notes made during the removal steps and the appropriate section and wiring diagrams in the service manual and proceed as follows a Insert each socket terminal from the left side switch harness into the correct cavity of the gray socket housing removed earlier b Insert each socket terminal from the right side switch harness into the correct cavity of the black socket housing removed earlier c Insert each socket terminal leading from the turn sig nals into the correct cavity of the Multilock socket housing removed earlier d Install the clips and or wire guides saved earlier w Touring Models Route switch and turn signal socket housings into the headlamp nacelle A Connect the gray 6 way switch wire socket housing coming from the bottom center of the handlebar to the gray 6 way pin housing Connect the black 6 way switch wire socket housing to the black 6 way pin housing a Connect the black 6 way Multilock connector coming from the bottom center of the handlebar to the black 6 way Multilock pin housing WARNING When servicing the fuel system do
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