Heated Hand Grip Kit Instruction Sheet - Harley
Contents
1. MOTOR HARLEY DAVIDSON UY J05296 INSTRUCTIONS REV 2010 12 22 HEATED HAND GRIP KIT GENERAL Kit Number 56100034 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 NOTE See the P amp A Retail Catalog or the Parts and Accessories section of www harley davidson com English only for a col lection of matching Genuine Motor Accessory items that are available These can be easily installed at the same time as this kit Additional Parts Required 2008 and 2009 models require purchase of additional parts e Twist grip sensor TGS jumper harness 70415 08A 1 e Connector 72902 01BK 1 e Terminal pin 72990 01 2 Service Manual Required 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 references service manual information A service manual for your model motorcycle is required for this installation and is available from a Harley Davidson Dealer Electrical Overload NOTICE It is possible to overload your vehicle s charging system by adding too many electrical accesso2. Handgrip power connector 3 has a cap that must be removed before connecting to vehicle wiring 2 See Figure 5 Connect power connector half from left handgrip to handgrip power connector 3 3 Connect 1 to left side handgrip connector 3of6 4 For 2008 and 2009 Models Only a Remove wiring from back of cigarette lighter Obtain harness assembly from kit Connect terminals from harness to cigarette lighter b Be sure to match the wire colors before splicing Install wiring removed from cigarette lighter in pre vious step to tabs on harness c Connect TGS main harness connector from jumper harness to connector 2 NOTES In next step be sure to match the wire colors before splicing 5 l is06872 5 aa T n a s 2 Z s O 2 C7 oF a B O O COSS 3 gt Se 1 Interconnect connector 2 Twist grip sensor jumper harness connector 3 Heated handgrip power connector Connect heated handgrip connector half from left handgrip to right side heated grip interconnect connector 1 Refer to the service manual and follow the instructions given to install the outer fairing Figure 5 Fairing Wiring FLH Models FLTR Models 1 Refer to the service manual and follow the instructions given to remove the outer fairing Remove wiring from back of cigarette lighter Obtain har ness as
3. and also serves as a retention device for the throttle grip To remove the grip a slight tug may be necessary to release the index pins in the grip from the receptacle in the seal cap Upon removing the grip check the location of the seal cap If the seal cap is still fastened to the index pins inside the old throttle grip it can be discarded along with the grip If the seal cap is still fastened to the end of the twist grip sensor e See Figure 1 Insert a small screwdriver or other flat blade tool into the flat area on one side of the seal cap e Press the leg on the underside of the cap to free it from the slot at the end of the twist grip sensor Pry up one end of the cap e Repeat on the other side of the cap e Carefully remove the cap and discard it 1 of 6 Please dispose of materials responsibly is04612 is06870 1 Handlebar 1 TGS main harness connector 2 Throttl O E REON SENSO 2 Right side heated handgrip connector to left 3 Seal cap 3 side handgrip Figure 1 Remove Seal Cap 3 ToTGS 4 ToTGS heated grip wires NOTE Before removing twist grip sensor attach chaser wire to jumper melee INSTALLATION 2 For 2008 and 2009 Models Refer to the service manual and follow the instructions given to remove the twist grip Figure 3 TGS Jumper Harness Heated Grip Installation sensor TGS and TGS jumper harness NOTE 3 See Figure 2 Unplug TGS jumper harness from TGS and If a ch
4. aser wire was not used air pressure or an electrician s main harness and discard stock jumper harness 2 fish tape can be used to thread the wire harnesses completely through the handlebar 4 See Figure 3 Attach NEW TGS jumper harness to TGS a Connect connector 3 to TGS harness 1 For 2008 and 2009 Models Thread the twist grip sensor wire harnesses into the right side of the handlebar b Cut heat shrink tubing from twist grip and install con a While feeding the wiring into the handlebar gently nector housing and terminals following instructions in pull the connectors at the end of the jumper harness the service manual White wire is installed in cavity 1 to draw the twist grip sensor out the center of the and black wire is installed in cavity 2 handlebar c Connect connector 4 to heated grip connector b Fit the index tabs on the twist grip sensor into the slots in the handlebar One index tab and slot are smaller than the others to prevent improper assembly is06875 2 For All Models Thread the left side heated grip wire harness all the way through and out the center of the handlebar NOTE Make sure that the handlebar surface is smooth dry and thor oughly cleaned of all dirt 3 See Figure 4 Position the left side heated grip 4 so the larger diameter portion of the flange 5 is at the bottom Push the grip fully onto the handlebar 4 Position the lower switch housing beneath the grip so that the groo
5. n one side Carefully pull the plug out from the grip through the out board opening NOTE Make sure that the handlebar surface and the inside of the new throttle grip are smooth dry and thoroughly cleaned of all dirt 13 Slide the new heated throttle grip over the end of the handlebar Rotate the grip to verify that the internal splines are engaged with those on the twist grip sensor 14 Refer to Figure 4 which shows the similar left side switch mounting Position the lower switch housing beneath the grip so that the grooves 2 on the outboard side of the switch housing fit over the flange on the end of the grip 15 Position the upper switch housing over the handlebar and lower switch housing 16 Start the upper and lower switch housing screws but do not tighten Verify that the wire harness conduit runs in the depression at the bottom of the handlebar 17 Position the brake master cylinder housing inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the bottom of the master cylinder housing J05296 18 Align the hole in the handlebar clamp with the hole in the master cylinder housing and start the lower screw with flat washer Adjust the switch housing and brake hand control position for rider comfort 19 Using a T 27 TORX drive head tighten first the upper then the lower handlebar clamp screws to 60 80 in Ibs 6 8 9 Nm NOTE Do not pull the switch housing s
6. nge white wire into one end of splice connector In other end of splice connector insert other orange white wire with red wire from adapter harness f Repeat procedure for black wires Models without fender tip light a See Figure 7 Locate fender tip light wiring 2 b Cut wires 2 in 5 08 cm from connector c Strip a 3 8 inch 9 5 mm section of insulation from the ends of the kit harness and vehicle wires d See Figure 8 Insert the orange white wire from step 4b into one end of the sealed splice connector Insert the red wire from adapter harness into the other end of the sealed splice connector e Repeat procedure for black wires 4 of 6 All Road King Models 1 Match the color of the sealed splice connector with the color of the crimp cavity of the crimping tool Crimp the wires into the connector 2 Repeat all the above procedures for the opposite side 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 fr
7. o far inboard as to cause the throttle grip to bind or drag on the handlebar Actuate the throttle grip to verify that it freely returns to the idle position 20 Using a I 25 TORX drive head tighten first the lower then the upper switch housing screws to 35 45 in Ibs 4 5 4 Nm 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 21 Verify that the right grip throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing NOTE The terminal sockets on the twist grip sensor are offset to one side and the pins can only be inserted one way 22 Using a needle nose pliers or similar tool carefully grasp the round plastic plug at the outboard end of the throttle grip a Insert the plug back through the opening in the grip and insert the terminal pins into the sockets at the end of the twist grip sensor engaging the two legs of the plug into the throttle grip sensor openings b Press the plastic plug firmly to verify that the pins are fully seated in the sockets 23 Install the end cap onto the end of the throttle grip CONNECTION TO VEHICLE WIRING FLH Models 1 Refer to the service manual and follow the instructions given to remove the outer fairing NOTE See Figure 5
8. om tool tip area and heat shrink attachment 3 Using the UltraTorch Heat Gun with Heatshrink Attach ment or suitable radiant heating device heat the crimped splice to encapsulate the sealed splice connection Apply heat from the center of the crimp out to each end until the meltable sealant comes out of both ends of the connector 4 Connect power connector half from left handgrip to har ness connector half 5 See Figure 7 Connect TGS connector half from right handgrip to harness connector half 1 6 Connect interconnect connector half from left handgrip to interconnect connector half from right side handgrip 7 Refer to the service manual and follow the instructions given to install the headlamp isO6866 1 TGS jumper harness connector 2 Front fender tip lamp jumper harness connector Figure 7 Road King Headlamp Wiring J05296 is01037 ol Stripped wire ends inserted into connector Wire ends crimped in connector Connector after heat has been applied oN Figure 8 Sealed Splice Connections Return to Service NOTE DO NOT perform the following steps until the heated hand grips and all related wiring have been installed according to the procedures outlined in this instruction sheet 1 Verify that the right grip throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing DO NOT operate the vehicle unless the throttle functions properly NOTE To p
9. revent battery drain these heated hand grips are designed to function only with the engine running The hand grips pro duce peak heat with the engine running at cruising speed The heat settings on the heated hand grip control dial range from 1 minimum to 6 peak 2 Before starting the vehicle check that the hand grips are not producing heat 3 Start the engine and check the hand grips at all settings for proper heating 5 of 6 SERVICE PARTS isO6863 Figure 9 Service Parts Heated Hand Grip Kit Table 1 Service Parts Item Description Quantity Part Number 1 Left heated handgrip 1 56209 10 2 Right heated handgrip 1 56249 10 3 Right heated handgrip cap 1 56250 10 4 Adapter harness 1 69200232 5 Splice connector 2 70586 93 J05296 6 of 6
10. ries If the combined electrical accessories operating at any one time consume more electrical current than the vehicle s charging system can produce the electrical consumption can discharge the battery and cause damage to the vehicle s electrical system See an authorized Harley Davidson dealer for advice about the amount of current consumed by addi tional electrical accessories or for necessary wiring changes 00211c J05296 sMany Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled WARNING When installing any electrical accessory be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modi fied Exceeding the maximum amperage can lead to elec trical failures which could result in death or serious injury 00310a This Heated Hand Grip kit requires up to 3 5 amps additional current from the electrical system Kit Contents Kit contains one pair of heated hand grips plus connecting parts See Figure 9 and Table 1 REMOVAL Preparation WARNING To prevent accidental vehicle start up which could cause death or serious injury remove main fuse before pro ceeding 00251b 1 Refer to the service manual and follow the instructions given to remove the handgrips NOTES The twist grip sensor in the right side of the handlebar has a seal cap that protects internal electrodes from dirt and moisture
11. sembly from kit Connect terminals from harness to cigarette lighter NOTES In next step be sure to match the wire colors before splicing 3 Install wiring removed from cigarette lighter in previous step to tabs on harness Connect power connector half from harness to vehicle harness connector half See Figure 6 Connect TGS connector half from right handgrip to harness connector half Connect interconnect connector half from left handgrip to interconnect connector half from right side handgrip J05296 re Refer to the service manual and follow the instructions given to install the outer fairing is06873 Figure 6 Twist Grip Sensor Jumper Harness Connector FLTR models Road King Models NOTE Be sure to match the wire colors before splicing See Figure 9 Obtain harness assembly from kit Cut the two spade terminals from harness Refer to the service manual and follow the instructions given to remove the headlight assembly Models with fender tip light a See Figure 7 Locate fender tip light wiring b See Figure 9 Splice into fender tip light wiring near connector using two splice connectors 5 from kit c Cut orange white and black wires approximately one inch 2 52 cm from connector d Strip a 3 8 inch 9 5 mm section of insulation from the ends of the kit harness and vehicle wires e See Figure 8 From cut ends insert one ora
12. ves 2 on the outboard side of the switch housing fit over the flange on the end of the grip 5 Position the upper switch housing over the handlebar and lower switch housing 1 Heat shrink tubing 2 2008 2009 stock jumper harness 6 Start the upper and lower switch housing screws but do not tighten Verify that the wire harness conduit runs in Figure 2 2008 and 2009 TGS and Harness the depression at the bottom of the handlebar 7 Position the clutch hand lever assembly inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket 8 Align the hole in the handlebar clamp with the hole in the clutch lever bracket and start the lower screw with flat washer Adjust the switch housing and clutch hand control position for rider comfort J05296 2 of 6 9 Using a I 27 TORX drive head tighten first the upper then the lower handlebar clamp screws to 60 80 in Ibs 6 8 9 Nm 10 Using a T 25 TORX drive head tighten first the lower then the upper switch housing screws to 35 45 in Ibs 4 5 4 Nm is01283 Switch housing screws Grooves Handlebar clamp Left handlebar grip Larger diameter of flange oe eh Figure 4 Left Handlebar Switch Housing 11 Obtain the new right side heated throttle grip 2 from the kit 12 Tucked inside the outboard end of the throttle grip is a round plastic plug with two pin terminals o
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