Handlebar Kit Instruction Sheet - Harley
Contents
1. ARNING 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 Lines must not catch on headlamp hardware or pass in front of headlamp e Lines must not catch on turn signal mounting hard ware or turn signals Lines must not catch on fuel cap Lines must not catch on speedometer e Make sure that lines are not pinched between the frame and or forks e Make sure that clutch line does not pull tight when handlebar is turned fully to left or right fork stops e Make sure control wires jumpers do not pull tight when handlebars are turned fully to left or right fork stops 1 Verify that the ignition light key switch is turned to OFF Install main fuse 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 2 Turn the ignition light key switch to IGNITION but do not start the engine Test all switches and lights for proper operation J04796 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 SERVICE PARTS is05621b Figure 2 Service Parts Handlebar2. Kit Table 1 Service Parts Item Description Quantity Part Number 1 Handlebar Not Sold Separately 2 Conduit black mesh for non 70017 06 FXDF models only 3 Cable tie 4 not shown 10181 2 of 2
3. cMOTOR HARLEY DAVIDSON WY J04796 INSTRUCTIONS REV 2015 04 21 HANDLEBAR KIT GENERAL Kit Number 55977 09A Models Ask a Harley Davidson dealer or refer to the latest Harley Davidson Genuine Motor Accessories and Genuine Motor Parts catalog to determine if this handlebar can be installed on your motorcycle This kit does not fit models equipped with Heated Hand Grips Softail Nacelle Kit 67907 96 Hydraulic Clutch Kits handlebar mounted gauges or the Road Tech Radio Additional Parts or Accessories Required Separate purchase of additional parts or accessories may be required for proper installation of this handlebar kit on your model motorcycle Refer to the latest Harley Davidson Genuine Motor Accessories and Genuine Motor Parts catalog for a list of required parts or accessories for your model Loctite 271 Red Threadlocker and Sealant 99671 97 is required for the proper installation of this kit Fresh uncontaminated brake fluid is also needed Refer to your owner s manual or the service manual to determine the correct brake fluid IWIN NIN 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 reuse the original brake line the two sealing gaskets found at each banjo fitting must be replaced Refer to the appropriate Parts Catalog or see a Harley Davidson dealer for the
4. correct part numbers Motorcycles equipped with a glued left side hand grip 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 IWAN IN The rider s safety depends upon the correct installation of this kit Use the appropriate service manual procedures If the procedure is not within your capabilities or you do not have the correct tools have a Harley Davidson dealer perform the installation Improper installation of this kit could result in death or serious injury 00333a J04796 Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled 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 2 and Table 1 REMOVAL See the service manual for removal procedures INSTALLATION See the service manual and follow the wiring procedures NOTE For Non FXDF Models Only See Figure 2 Cut the mesh tubing from the kit into two equal length pieces Slide the switch wire bundles through mesh conduit Position conduit into switch control housing Tie each end of conduit with cable strap from kit Handlebar Installation See the service manual and follow the installation procedure
5. s For 2016 and later Softail Models Reuse the stock twist grip sensor with the smaller internal wire bundle NOTE This installation is not compatible with heated hand grips so the shorter heated handgrip portion 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 1 Tape the ends of the longer pair of harness bundles together tight enough to be passed easily through the handlebar Apply a light coat of liquid soap window cleaner or all purpose lubricant to the twist grip sensor wire bundle 2 See Figure 1 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 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 1 of2 Please dispose of materials responsibly is08588a Center wiring hole Upper switch mounting screw Lower switch mounting screw PO OPens Twist grip sensor Position inside switch edge pinch point above wires and hole in handlebar Keep wires clear of pinch points near threaded post Figure 1 Switch Housing and Twist Grip Sensor Wire Routing 2016 and Later Softail SAFETY CHECK W
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