INSTRUCTIONS - Harley
Contents
1. WARNING A Service Manual is required to install this kit The rider s safety depends upon the correct installation of this kit If the procedure is not within your capabilities or you do not have the correct tools have any Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury NOTE A Service Manual for your model motorcycle can be pur chased from any Harley Davidson dealer Preparation WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 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 Refer to the Service Manual and follow the instructions to remove the seat and disconnect the battery cables negative cable first Retain all seat mounting hardware WARNING Gasoline is extremely flammable and highly explosive When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Inadequate safety precautions can result in death or serious injury 2 Loosen the fuel tank Refer to FUEL TANK PARTIAL REMOVAL in the appropriate section Carbureted or EFI Engine of the Service Manual 3 Bleed the brake fluid from the front b2. clamp screws to 60 80 in Ibs 6 8 9 0 Nm 11 Using a T25 TORX drive head tighten first the lower then the upper handlebar switch housing screws to 35 45 in Ibs 4 0 5 1 Nm 12 Verify that the right grip throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing Final Assembly Awarninc Do not re use brake line gaskets Use of original brake line gaskets could cause front brake failure and loss of control which could result in death or serious injury J02970 CAUTION To avoid leakage verify that the washers banjo bolt brake line and caliper bore are completely clean 1 See Figure 4 and the Service Parts illustration Use the stock banjo bolts and new brake line gaskets items 6 and 7 from the kit to fasten the new braided front brake line assembly 4 between the front brake master cylinder and the front brake calipers Replace the stock P clamps with the new clamps 8 and 9 from the kit Route the brake line through the new clamps and adjust as necessary Torque the banjo bolts to 17 20 ft lbs 23 30 Nm Torque the brake line manifold screw to 10 15 ft lbs 13 6 20 3 Nm 104849 2 is e 4 Ze Braided Front Brake Line Assembly Stock Banjo Bolt New Gasket 44 inches New Gasket 38 inches Figure 4 Front Braided Brake line Assembly 2 Bleed the brakes See BLEEDING HYDRAULIC BRAKES in the Service Manual Safety Check 1 Turn
3. MTOR HARLEY DAVIDSON AUA J02970 INSTRUCTIONS REV 8 04 03 Kit Number 56369 03 STREET SLAMMER HANDLEBAR KIT FOR SOFTAILS General This kit is designed for installation on 2000 and later FX Softail except FXSTS FLSTF and FLSTC model motorcycles NOTE This kit does not fit with Heated Handgrips Softail Nacelle Kit part number 67907 96 Hydraulic Clutch Kits or Mini Tach Kits on any of the above models NOTE Installing this kit also requires installing new hand grips which are sold separately Refer to the latest Harley Davidson Parts and Accessories Catalog for a selection of hand grips In addition to the Handlebar Kit for each of the Softail models listed below these additional part numbers are required FXST Black clutch cable 38664 00 OR Braided clutch cable 56414 03 Black throttle idle cable 56431 98 OR Braided throttle idle cable 56345 03 Front directional mounting kit 68266 03 FXSTB Stock black clutch cable OR Braided clutch cable 56411 03 Stock black throttle idle cable OR Braided throttle idle cable 56345 03 FXSTD Black clutch cable 38665 00 OR Braided clutch cable 56411 03 Braided throttle idle cable 56392 03 Front directional mounting kit 68266 03 FLSTF and FLSTC Black clutch cable 38665 00 OR Braided clutch cable 56411 03 Black throttle idle cable 56431 98 OR Braided throttle idle cable 56345 03 See the Service Parts illustration for a list of items contained in this kit
4. h and turn signal wiring through the handlebar Switch operation without the grommets in place may damage the wires causing a short circuit which could result in death or serious injury 1 Remove the wiring retainers from both switch harnesses NOTE The grommets installed in the next step will later be maneuvered into position in the handlebar after the wiring is routed through the handlebar 2 See the Service Parts illustration Slide one large grom met 2 onto each of the switch wire bundles Slide one small grommet 3 onto each of the turn signal wire pairs 3 Apply a light spray of all purpose lubricant such as WD 40 to the right side switch wire bundle and turn signal wire pair 4 Take two pieces of string that are approximately 3 5 feet long and tie a small spare nut to one end of both strings Place the new handlebar so that the riser ends are upward Insert the nut with the strings attached into the right side riser wiring hole and tip the handlebar so that the nut slides out the right grip end of the handle bar Remove the spare nut from the strings and with a tweezers fish one string out through the switch wiring hole and the other string out the turn signal wiring hole Ensure the opposite ends of the strings are still extend ing out the riser hole 2 of 6 Wiring in the switch housings must be routed carefully and exactly as shown Pinch points in the switch housings can short circuit or sever wires wh
5. h pin connector from the left side wire bundle into the correct cavity of the GRAY female Deutsch pin connector removed in Removing the Stock Handlebar step 12 on Page 2 14 Insert each pin connector from the right side wire bun dle into the correct cavity of the BLACK female Deutsch pin connector removed earlier Installing the New Handlebar 1 Install the new handlebar onto the upper triple clamp using the saved hardware Torque the riser bolts to 25 30 ft lbs 34 41 Nm 2 See the Service Parts Illustration Connect the 6 place Deutsch connectors coming from the bottom center of the handlebar to the correct main harness connectors under the fuel tank Match the gray harness connector to the gray left hand switch control connector and the black harness connector to the black right hand switch control connector 3 Route both turn signal wires down through large oval opening in center of upper triple tree behind front riser cover 3 of 6 4 Follow routing noted in earlier step left turn signal wires to left side of frame right turn signal wires to right side of frame route until wiring arrives near turn signal connector Install clips and or wire guides saved in earlier step Use wire ties to secure turn signal wiring to switch wiring along the route 5 On right side turn signal 2 place connector follow notes saved from removal step and instructions under Amp Multilock Connectors in Service Manual to install two 2 p
6. ice Manual for removal of the right side switch housing assembly This is necessary to access the throttle cables 7 Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables from the existing right grip throttle sleeve assembly 8 Using a T25 TORX drive head remove the switch hous ings and attached wiring from the stock handlebar Refer to HANDLEBAR SWITCHES in the Service Manual 9 See Figure 1 Remove and discard the four hex socket head screws 1 holding the stock handlebar upper clamp 2 Remove the upper clamp and discard 10 Remove the handlebar 3 from the motorcycle 11 Remove and discard the stock handlebar risers 4 Save the remaining hardware for later installation NOTE DO NOT remove the wires from the male Deutsch connec tors behind the fuel tank 12 Note the wire positions in the female Deutsch connec tors leading from the switches Refer to the wiring dia gram and the DEUTSCH ELECTRICAL CONNECTORS section in the Service Manual Remove the wires from the connectors J02970 i04845C All Models Except FXSTD FXSTD Clamp screw 4 Upper clamp Handlebar Handlebar risers Figure 2 Removing the handlebar cover 13 Bind the loose pin terminal ends of each of the switch wire bundles and the turn signal wire bundles with tape Wiring the New Handlebar Grommets in each of the wiring holes in the handlebar must be in position after routing the switc
7. ich could cause loss of vehicle control resulting in death or serious injury 5 See Figure 3 Tie the end of the string from the switch wire hole to the switch wire bundle Gently feed the wire bundle into the right side wire hole and pull the bundle down through the handlebar and out the riser hole Ensure the turn signal string stays in place as the switch wire is fed through the handlebar Tie the end of the string coming from the turn signal wire hole to the turn signal wire Gently feed the wire into the hole and pull the wire through the handlebar and out the riser hole i04486a Position the inside switch edge pinch point above wires and handlebar hole Upper switch housing screw Ka C Ww Keep wires clear of pinch points near threaded post Lower switch housing screw Figure 3 Switch Housing wire routing Right Side Housing Shown Awarnine Carefully pull the control wires through the hole in the riser of the handlebar to prevent stripping the wires Stripped wires can cause short circuits and damage the vehicle electrical components which could cause loss of vehicle control resulting in death or serious injury 6 Insert the switch wire grommet into place in the switch wire hole in the handlebar Insert the turn signal grom met into place in the turn signal hole in the handlebar Slide one large grommet 2 onto both of the wire bun dles sticking out of the riser wire hole and insert the gro
8. lace terminals to Amp connector Connect male and female con nector halves Repeat this step for the left turn signal wiring and connector WARNING Gasoline is extremely flammable and highly explosive When servicing the fuel system do not smoke or allow open flame or sparks in the vicinity Inadequate safety precautions can result in death or serious injury 6 Tighten the fuel tank Refer to FUEL TANK INSTALLA TION AFTER PARTIAL REMOVAL in the appropriate section Carbureted or EFI Engine of the Service Manual 7 Follow instructions in the Service Manual to install a new right grip throttle sleeve to the handlebar and con nect the throttle cables NOTE If the handlebar grips are patterned align the pattern on the left grip with the pattern on the right grip with the throttle in the fully closed position 8 Install a new handlebar grip on the left end of the new handlebar according to the handlebar grip instruction sheet 9 Adjust the positions of the switch housings and the clutch and brake lever assemblies on the handlebar for rider posture and comfort The brake master cylinder must be horizontally level NOTE Tighten the lower switch housing screw before tightening the upper switch housing screw This will leave any gap in the switch housing at the front of the switch housing assembly for best appearance 10 Using a T27 TORX drive head tighten first the upper then the lower brake lever and clutch lever
9. mmet into the riser hole in the handlebar 7 Repeat steps 3 through 6 for the left side switch wires and turn signal wires J02970 Awarnine Avoid the pinch points shown in Figure 3 Pinch points in the switch housings can short circuit or sever wires which could cause loss of vehicle control resulting in death or serious injury Grommets in each of the wiring holes in the handlebar must be in position after routing the switch and turn signal wiring through the handlebar Switch operation without the grommets in place may damage the wires causing a short circuit which could result in death or serious injury 8 Loosely fasten the brake lever and clutch lever clamps to the new handlebar 9 Loosely fasten the handlebar switch housings to the new handlebar 10 ON FXST and FXSTD models install the Front Directional Mounting Kit part number 68266 03 NOTE It is necessary to install the Front Directional Mounting Kit onto the FXST and FXSTD models to avoid contact between the front turn signals and the fuel tank during vehicle opera tion 11 Remove the tape from the ends of the wire bundles 12 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 13 Refer to the wiring diagram and the DEUTSCH ELEC TRICAL CONNECTORS section in the Service Manual Insert eac
10. om automati cally returning to idle can lead to a loss of control which could result in death or serious injury WARNING After completing this installation and bleeding the sys tem always test motorcycle brakes at low speed If brakes are not operating properly or braking efficiency is poor testing at high speeds could result in death or serious injury CAUTION Carefully pull the wires through the hole in the riser of the handlebar to prevent stripping the conduit and wires Stripped wires can damage the vehicle electrical components 5 of 6 Service Parts Part Number 56369 03 Date 8 03 Street Slammer Handlebar Kit i04850a Stock Hardware for all models except FXSTD Stock Hardware for FXSTD Description Qty Part Number Handlebar 56386 03 Handlebar grommet large 4 11386 Handlebar grommet small 2 11398 Braided front brake line kit contains items 5 10 45264 98B Braided brake line 45265 98A Brake line gasket 38 D 2 41731 88A Brake line gasket 44 I D 2 41733 88 P clamp 68562 84 P clamp 71795 63A Cable strap not shown 10065 SCOONDAKRWPDY J02970 6of6
11. rakes See BLEED ING HYDRAULIC BRAKES in the Service Manual Removing the Stock Handlebar CAUTION Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching Damage to the finish could result CAUTION Damaged banjo bolt surfaces will leak when reassem bled Prevent damage to seating surfaces by carefully removing brake line components 1 Remove the brake line that runs from the front brake master cylinder to the front brake caliper See FRONT BRAKE MASTER CYLINDER in the Service Manual 2 Using a T27 TORX drive head remove the front brake master cylinder and clutch lever assemblies refer to CLUTCH CABLE in the Service Manual from the stock handlebar 3 Disconnect the handlebar control wiring from the gray and black 6 place main harness connectors under the fuel tank NOTE When performing the following step note left and right turn signal wire routing 4 See Figure 1 Separate the left and the right turn signal Amp 2 place connector halves NOTE Prior to performing the following step make a note of con nector pin socket location number with regard to wire color of each pin Figure 1 Turn Signal 2 Place Amp Connector 5 Following instructions under Amp Electrical Connectors in Service Manual remove pins from right turn signal 2 place connector Repeat this step for the left turn signal connector 6 Refer to the RIGHT HANDLEBAR SWITCH section of the Serv
12. the handlebar to the left and right steering stops testing the handlebar control functions at each stop Awarnine Clutch cables must not pull tight when handlebars are turned fully to left or right fork stops Be sure wires and cables are clear of fork stops at steering head so they will not be pinched when fork is turned against stops Steering must be smooth and free with no binding or interference Interference with steering could result in loss of vehicle control and death or serious injury 4 of 6 Awarnine Connect positive battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00068a 2 Connect the negative battery cable 3 Turn the Ignition Light Key Switch to IGNITION and test each handlebar switch for proper operation 4 Apply the front brake hand lever to test operation of the brake lamp 5 Refer to the Service Manual and follow instructions to install the seat WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a J02970 WARNING Prior to starting engine verify that the throttle control will snap back to the idle position when released A throttle control that prevents the engine fr
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