INSTRUCTIONS - Harley
Contents
1. Replace the stock P clamps with the new clamps 10 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 2 Bleed the brakes See BLEEDING HYDRAULIC BRAKES in the Service Manual Safety Check 1 Turn the handlebar to the left and right steering stops testing the handlebar control functions at each stop WARNING 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 WARNING Always connect the positive battery cable first If the positive cable should contact ground with the negative cable installed the resulting sparks may cause a battery explosion which could result in death or serious injury 2 Connect the battery cables positive cable first 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 4of5 Awarnine WARNING Afte2. the Service Manual to disconnect the throttle cables from the existing right grip throttle sleeve assembly 6 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 7 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 8 Remove the handlebar 3 from the motorcycle 9 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 10 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 11 Bind the loose pin terminal ends of each switch wire bundle with tape 1of5 104845 Handlebar riser Figure 1 Removing the handlebar cover Wiring the New Handlebar WARNING Grommets at each end of the handlebar must be in position during and after routing the switch wiring through the han dlebar Switch and wiring installation or 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 2 See
3. Improperly aligned handlebars can contact the fuel tank when turned to the left or right Contact with the fuel tank while riding can cause loss of vehicle control resulting in death or serious injury 5 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 cen tered raise the handlebar angle as necessary until proper clearance is obtained 6 Tighten the upper handlebar clamp screws as follows a Tighten the front screws until the upper handlebar clamps make contact with the handlebar riser b Tighten the rear screws to 12 16 ft lbs 16 3 21 7 Nm c Tighten the front screws to 12 16 ft lbs 16 3 21 7 Nm NOTE There will be a slight gap between the upper clamps and the risers toward the rear of the handlebars after tightening 7 Follow instructions in the Service Manual to install a new right grip throttle sleeve to the handlebar and con nect the throttle cables 3 of 5 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 co
4. cMOTOR2 HARLEY DAVIDSON WY General J02556 This kit fits 2000 and later FLSTC model motorcycles Installing this kit also requires installing new hand grips sold separately Refer to the latest Harley Davidson Parts and Accessories Catalog for a selection of hand grips See the Service Parts illustration for a list of items contained in this kit 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 your 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 your Harley Davidson dealer Preparation To protect against shock and accidental start up of vehi cle disconnect the battery cables negative cable first before proceeding Inadequate safety precautions could result in death or serious injury Always disconnect the negative battery cable first If the positive battery cable should contact ground with the nega tive cable installed the resulting sparks may cause a bat tery explosion which could result in death or serious injury 1 Remove the seat and disconnect the battery cables negative cable first Gasoline is extremely flammable and highly explosive When servicing the fuel system do
5. formed Be sure to turn the ON OFF switch to the OFF position after use 16 Use a heat gun or suitable radiant heating device to shrink the heat shrink tubing to the wire bundles J02556 Installing the New Handlebar 1 Install the new handlebar risers 6 from the kit using the saved hardware Torque the riser bolts to 25 30 ft Ibs 34 41 Nm Center the new handlebar on the risers To make sure that the handlebar is centered verify that the knurled areas on the outboard side of each riser are equal 2 Position the new upper handlebar clamps 3 and install with new clamp screws 1 and flat washers 2 from the kit Snug the upper screws but do not fully tighten 3 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 Awarnine 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 4 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 AwarnineG
6. mfort 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 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 i04849 S banjo bolt D TF New 44 gaskets Braided front brake line assembly Stock banjo bolt New 38 gaskets Figure 3 Front Braided Brake line Assembly J02556 Final Assembly WARNING 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 CAUTION To avoid leakage verify that the washers banjo bolt brake line and caliper bore are completely clean 1 See Figure 3 and the Service Parts illustration Use the stock banjo bolts and new brake line gaskets items 8 and 9 from the kit to fasten the new braided front brake line assembly 7 between the front brake master cylinder and the front brake calipers
7. n Removing the Stock Handlebar step 10 on Page 1 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 WARNING 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 the wires with shrink tubing can cause short circuits or sev ered wires which could cause loss of vehicle control resulting in death or serious injury NOTE The heat shrink tubing on the wire bundles exiting the bot tom center of the handlebar must be installed to protect the wires from damage and short circuits at the wire exit hole on the handlebar 15 Position the heat shrink tubing installed on the wire bundles in step 10 above in the area of the center wire exit hole on the handlebar Use extreme caution when operating the UltraTorch UT 100 or any other radiant heating device Read the manufacturer s instructions carefully before using the tool Improper tool handling can result in death or serious injury Always keep hands away from tool tip area and heat shrink attachment Avoid directing the heat toward any fuel system com ponent Extreme heat can cause fuel ignition explo sion resulting in death or serious injury Avoid directing heat toward any electrical system component other than the connectors on which heat shrink work is being per
8. nch 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 at each end of the handlebar must be in position after routing the switch wiring through the handlebar Vehicle operation without the grommets in place may dam age the wires causing a short circuit which could result in death or serious injury 7 See the Service Parts illustration Check that the grommets 5 are still in place in the holes at the ends of the handlebar 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 2of5 Wiring the New Handlebar Continued 10 See the Service Parts illustration Cut the heat shrink tubing 11 from the kit into two equal pieces Slide one piece of the tubing over the end of each wire bundle exiting the bottom center of the handlebar 4 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 each pin connector from the left side wire bundle into the correct cavity of the GRAY female Deutsch pin connector removed i
9. 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 brakes See BLEED ING HYDRAULIC BRAKES in the Service Manual INSTRUCTIONS REV 05 16 2002 Kit Number 56364 02 FLSTC BEACH HANDLEBAR KIT 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 4 Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual for removal of the right side switch housing assembly This is necessary to access the throttle cables 5 Refer to the THROTTLE CONTROL section of
10. r installing seat pull upward on front of seat to be After completing this installation and bleeding the sys sure it is locked in position If seat is loose it could tem always test motorcycle brakes at low speed If result in shifting during vehicle operation loss of con brakes are not operating properly or braking efficiency trol of vehicle death or serious injury is poor testing at high speeds could result in death or serious injury Awarninc 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 from automati cally returning to idle can lead to a loss of control which could result in death or serious injury MOTOR Part No 56364 02 Date 05 02 SMOTDR e SUN Service Parts FLSTC Beach Handlebar Kit i04850 Description Part No Cap screw 5 16 18 x 1 1 2 4 4816A Washer 4 6046 Handlebar upper clamp 2 56016 02 Handlebar 56553 02 Handlebar grommet 2 11403A Riser 2 56383 02 Braided front brake line assembly 45783 02 Brake line gasket 44 ID 2 41733 88 Brake line gasket 38 ID 2 41731 01 P Clamp 3 68562 84 Heat shrink tube 72162 02 OOANDAaAAKRWND J02556 5 of 5
11. the Service Parts illustration Check that the grom mets 5 are in place in the holes near each end of the handlebar 3 Apply a light spray of all purpose lubricant such as WD 40 to the right side switch wire bundle Wiring in the switch housings must be routed carefully and exactly as shown Pinch points in the switch hous ings can short circuit or sever wires which could cause loss of vehicle control resulting in death or serious injury 4 See Figure 2 Route the wire bundle through the switch housing as shown Gently feed the wire bundle into the right side grommeted hole and toward the center of the new handlebar J02556 104486 Upper switch housing screw C Keep wires clear of pinch points near threaded post Position the inside switch edge pinch point above wires and handlebar Lower switch housing screw Figure 2 Switch Housing Wire Routing Right Side Housing Shown Awarnine Carefully pull the control wires through the hole in the bottom center of the handlebar to prevent stripping the wires Stripped wires can cause short circuits and dam age the vehicle electrical components which could cause loss of vehicle control resulting in death or serious injury 5 Pull the taped end of the wire bundle through the wire exit hole at the bottom center of the handlebar 6 Repeat Steps 3 through 5 for the left side switch wires Awarnine Avoid the pinch points shown in Figure 2 Pi
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