HEATED HAND GRIP KITS - Harley
Contents
1. Item Description Quantity Part Number Item Description Quantity Part Number Kit 56047 03C Flame Heated Hand Grips 2 Heated hand grip right 56925 05 1 Heated hand grip left 56100 04B Kit 56926 05A Skull Heated Hand Grips 2 Heated hand grip right 56048 03 1 Heated hand grip left 56927 05 Kit 56107 03B Smooth Grain Leather Heated Hand Grips 2 Heated hand grip right 56928 05 1 Heated hand grip left 56169 04A Kit 56997 07A Ironside Heated Hand Grips 2 Heated hand grip right 56136 03 1 Heated hand grip left 57055 07 Kit 56174 03C Chrome Rubber Large Diameter Grips 2 Heated hand grip right 56053 07 1 Heated hand grip left 56181 04B Kit 56100030 Slipstream Heated Hand Grips 2 Heated hand grip right 56175 03 1 Heated hand grip left 56100038 Kit 56196 03C Chrome Rubber Small Diameter Grips 2 Heated hand grip right 56100033 1 Heated hand grip left 56617 04A Kit 56100111 Airflow Heated Hand Grips 2 Heated hand grip right 56615 03 1 Heated hand grip left 56100109 Kit 56512 02C Contoured Chrome Rubber Heated Grips 2 Heated hand grip right 56100127 1 Heated hand grip left 56514 04A Parts common to ALL Heated Hand Grip Kits 2 Heated hand grip right 56513 02 3 Sealed splice connector 2 70586 93 Kit 56619 03B Nostalgic Heated Hand Grips 4 Ring terminal 2 for 10 stud 9857 1 Heated hand grip left 56638 03A 5 Ring terminal 2 9858 2 Heated hand grip right 5662. 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 refers to service manual information A service manual for this year 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 accessories 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 0021 1c 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
3. J02983 WARNING Gasoline can drain from the carburetor fuel line when disconnected from fuel valve fitting Gasoline is extremely flammable and highly explosive which could result in death or serious injury Wipe up spilled fuel immediately and dispose of rags in a suitable manner 00256a 2 Turn the fuel supply valve to OFF Remove the fuel line from the valve For ALL models EXCEPT VRSC WARNING 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 3 Refer to the service manual to remove the instrument console if equipped from the fuel tank 4 See the correct section Carbureted or EFI Engine of the service manual for fuel tank removal instructions 5 For FLHR models or for 1996 and later FL Softail models with Chrome Headlight Nacelle Kit H D Part No 67907 96 Refer to the service manual to remove the handlebar shroud Current Hand Grip Removal For ALL Models Refer to the service manual to remove the right side handlebar switch housing assembly This is necessary to access the throttle cables N Refer to the service manual to disconnect the throttle cables and remove the current right grip throttle sleeve assembly After removal make sure that the handlebar end is clean and smooth w Loosen but do not remove the two screws with flat was
4. 2 Fuse block Figure 15 Accessory Fuse Locations V Rod Models For ALL models Verify that there is sufficient slack in the orange white lead so that handlebar movement will not be restricted Proceed to the RED LEAD CONNECTION section for the specific model J02983 RED LEAD CONNECTION TO BATTERY POWER SOURCE Use the service manual wiring diagrams for a specific model and year vehicle to locate a power source that is fed directly from the battery 2003 Earlier Dyna Models The heated hand grip battery power source is the silver ter minal of the circuit breaker inside the electrical side cover 1 See Figure 16 Route the heated hand grip harness red wire through the top of the frame under the seat to the circuit breaker on the inside of the electrical side cover 2 See Figure 22 Select the correct ring terminal 4 5 or 6 from the kit to fit the silver terminal stud with the red wire on the circuit breaker 3 Cut the excess length from the heated hand grip harness red wire but DO NOT cut off the in line fuse holder Crimp the ring terminal to the end of the red wire per the Packard crimping tool instructions in the service manual appendix NOTICE The power wire red from the heated handgrip wire har ness must connect to the circuit breaker silver terminal Connecting to the circuit breaker copper terminal can cause circuit overload which could result in equipment damage 00370a 4 Install the
5. near the fuel tank 2 Select the correct ring terminal 4 5 or 6 from the kit to fit the ground screw 3 See Figure 2 Cut the black wire on the heated hand grip wire harness to easily reach the ground location and crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix 4 Install the ring terminal to the ground connection Secure per the torque specification in the service manual 5 Proceed to For ALL models in this section is01113 1 Tail lamp harness orange white wire 2 Ground terminal black wire Figure 2 Power and Ground Connections Dyna Models 2010 Earlier Softail Models 1 Remove the ground screw on the top of the frame under the seat near the fuel tank 2 Select the correct ring terminal 4 5 or 6 from the kit to fit the ground screw 3 Cut the black wire on the heated hand grip wire harness to easily reach the ground location and crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix 4 See Figure 3 Install the ring terminal onto the ground screw threads Fasten the ground screw to the frame 2 Secure per the torque specification in the service manual 5 Proceed to For ALL models in this section 4 of 14 La is01108a MO s N fi i aa 1 Tail lamp harness orange white wire 2 Ground terminal black wire 3 Bat
6. one of the chassis ground studs 3 Select the correct ring terminal 4 5 or 6 from the kit to fit the ground stud 4 Cut the black wire on the heated hand grip wire harness to easily reach the ground location Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix 5 Install the ring terminal to the ground connection Secure per the torque specification in the service manual 6 Proceed to For ALL models in this section 2006 Earlier V Rod Models 1 See Figure 6 Remove the screw 1 under the seat that fastens the ignition switch 2 to the right side of the frame 2 Scrape the paint from the top of the frame where the screw was removed to make a strong ground contact 3 Select the correct ring terminal 4 5 or 6 from the kit to fit the ignition switch screw J02983 4 Cut the black wire on the heated hand grip wire harness to easily reach the ground location Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix 5 Install the black wire ring terminal onto the threads of the ignition switch screw Install the screw to the ignition switch Tighten to 53 88 in lbs 6 10 Nm 6 Proceed to For ALL models in this section 1 Screw 2 Ignition switch Figure 6 Ground Connection 2006 and Earlier V Rod Models 2007 Later V Rod Models The heated hand grip harnes
7. terminal but DO NOT cut off the in line fuse holder Crimp the ring terminal to the end of the red wire per the Packard crimping tool instructions in the service manual appendix 3 Fasten the red wire ring terminal to the positive terminal mounting post on the battery Tighten the terminal fastener to 60 96 in Ibs 7 10 Nm For ALL models Verify that there is sufficient slack in the red lead so that handlebar movement will not be restricted Proceed to the next section RETURN TO SERVICE NOTE DO NOT perform the following steps until the heated hand grips and all related wiring have been installed per the proced ures outlined in this instruction sheet for your model motorcycle 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 Verify that the ignition switch is in the OFF position before installing the main fuse or attaching the battery cables IWIN NIN 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 2 For 2003 earlier Touring models only Refer to the service manual to attach the battery cables positive cable first Apply a light coat of petroleum jelly or corrosion retardant material
8. 0 Softail Models 2004 2011 Dyna Models 2004 2013 Sportster Models and 2004 2013 Touring Models The heated hand grip battery power source is the B battery positive connector on the main electrical harness 1 See Figure 20 Locate the B battery positive connector 1 ared wire with an unused gray connector on the main electrical harness a For Dyna and Softail models under the seat b For Sportster and Touring models routed under the seat beneath the ECM Electronic Control Module Remove the cover 2 from the connector 2 See Figure 22 Plug the adapter harness 10 from the kit into the B connector 3 Cut the heated hand grip harness red wire to within easy reach of the end of the adapter harness red wire but DO NOT cut off the in line fuse holder 4 Obtain a sealed splice connector 3 from the kit See Figure 7 the one into one splice configuration Splice the heated hand grip red wire to the adapter wire per the instructions in the service manual appendix 5 Proceed to For ALL models in this section is01107 1 B connector 2 Cover Figure 20 B Connector V Rod Models The heated hand grip harness red wire connects directly to the battery positive terminal J02983 1 Select the correct ring terminal 4 5 or 6 from the kit to fit the positive terminal fastener on the battery 2 Cut the heated hand grip harness red wire to within easy reach of the battery positive
9. 20 03 for 1A Ne ees Kit 56694 04A Diamond Plate Heated Hand Grips ee ae a 9 mm stud 3899 Heated hand grip left 59993 94A 7 Wire harness extension 70259 02 2 Heated hand grip right 56696 04 10 5 inch 26 7 cm long Kit 56750 04B Stealth Heated Hand Grips 8 Cable strap black 8 10006 1 Heated hand grip left 56734 04A 10 5 inches 26 7 om long 2 Heated hand grip right 56733 04 9 Wire fuse block adapter 70329 04 Kit 56828 03B Aileron Heated Hand Grips 10 1 vire harness adaptor 70910 04 1 Heated hand grip left 56830 03A 11 Clip wire retainer 4 70345 84 2 Heated hand grip right 56829 03 12 Fuse blade type 2A gray 54305 98 13 Fuse blade type 5A light tan 72331 95 F oy a r Kit 56923 05 H O G Heated Hand Grips inside fuse holder 1 Heated hand grip left 56924 05 J02983 14 of 14
10. 6 Remove the right side hand grip from the handlebar 7 Disconnect the connector on the right side grip from the left side grip wire harness 8 Check continuity across the two connector leads in the right side grip If the test shows continuity the hand grips are functional Hand Grips Produce Heat with Ignition Switch Off If the hand grips produce heat with the ignition switch off then either the hand grips are incorrectly wired to the vehicle or the left side grip and wire harness are faulty Carefully check all heated hand grip wire connections on the vehicle If the connections are correct replace the heated hand grip main wire harness then test the hand grips SO fo is01119a Left side hand grip Heat control Positive to main circuit breaker or battery connector Fuse Positive to accessory power Negative ground Right side hand grip ONT Oo Figure 21 Heated Hand Grip Schematic SERVICE PARTS See Figure 22 and Table 1 is01120b Figure 22 Service Parts Heated Hand Grip Kits J02983 13 of 14 Table 1 Service Parts Table 1 Service Parts
11. P lt 5 AMP POLICE CONTENT IN PARENTHESIS 1 P amp A IGN fuse location 2 Remove these fuses 3 Figure 14 P amp A IGN Fuse Cavity 2004 2007 Touring Models WITHOUT spring tabs from the wire and discard it V Rod Models The heated hand grip switched power source is an orange white O W main harness power lead coming from the fuse block 3 ALL models See Figure 14 Locate the fuse cavity marked P amp A IGN 2A MAX 1 There is a bus bar feeding one side of this circuit but no mating wire or fuse J02983 9 of 14 1 See Figure 15 Carefully slice open an area of the main harness wrap near the fuse block 2 at an accessible point and cut the orange white main harness wire leading to the fuse cavity 1 marked a ACCESSORIES on 2002 2006 models or b P amp A IGNITION on 2007 and later models 2 Cut the excess length from the orange white power lead of the heated hand grip wire harness to within easy reach of the cut orange white wires at the fuse block 3 See Figure 22 Obtain a sealed splice connector 3 from the kit See Figure 7 the two into one splice configuration Splice the heated hand grip wire harness power lead to the main harness orange white wires per the instructions in the service manual appendix 4 Install the 2A fuse 12 from the kit into the fuse cavity to complete the circuit isO6517 1 Accessories fuse
12. a rubber boot under the seat Place the Electrical Connection Harness at connector 91A but DO NOT connect at this time 2 Route the heated hand grip wires over to the Electrical Connection Harness DO NOT cut off the in line fuse holder on the red wire but cut the wires to a suitable length to easily reach the sealed splice connectors on the Elec trical Connection Harness 3 Splice the black hand grip wire to the black wires in the Electrical Connection Harness 4 Splice the orange white hand grip wire to the red yellow wires in the Electrical Connection Harness 5 Splice the red hand grip wire to the red blue wires in the Electrical Connection Harness 6 Use aheat gun or suitable radiant heating device to shrink the connector to the wires 7 Pull the rubber boot out from the gray Digital Technician pin connector 91A Cut the boot off of the wires 8 Connect the socket housing of the Electrical Connection Harness to connector 91 A 9 Insert the rubber boot into the open pin connector of the Electrical Connection Harness 10 Loosen or remove the four screws holding the ECM to the mounting bracket Route the Electrical Connection Harness J02983 under the ECM connector Tighten the four screws to 45 55 in lbs 5 1 6 2 Nm 11 Proceed to the RETURN TO SERVICE section BLACK LEAD CONNECTION TO GROUND 2011 Earlier Dyna Models 1 Remove the nut from the ground screw on the top of the frame under the seat
13. and grip switched power source is an orange white O W main harness power lead inside the elec trical side cover or under the seat 1 See Figure 11 Carefully slice open an area of the main harness wrap inside the electrical side cover or under the seat at an accessible point and cut an orange white main harness power lead 2 Cut the excess length from the orange white power lead of the heated hand grip wire harness to within easy reach of the cut orange white wires inside the side cover or under the seat 3 See Figure 22 Obtain a sealed splice connector 3 from the kit See Figure 7 the two into one splice configuration Splice the heated hand grip wire harness power lead to the main harness orange white wires per the instructions in the service manual appendix 4 Proceed to For ALL models in this section isO1106 1 Left side cover containing circuit breaker silver terminal red wire 2 Stock wire harness orange white wire Figure 11 Power Connections XL Models 2003 Earlier Touring Models The heated hand grip switched power source is an orange white O W main harness power lead inside the right side cover near the top 1 See Figure 12 Carefully slice open an area of the main harness wrap inside the electrical side cover at an accessible point and cut an orange white main harness power lead 2 Cut the excess length from the orange white power lead of the heated hand grip wire harness t
14. arness under the seat 1 See Figure 3 Carefully slice open an area of the tail lamp harness 1 wrap at an accessible point under the seat and cut the orange white wire 7 of 14 2 Cut the excess length from the orange white power lead of the heated hand grip wire harness to within easy reach of the cut orange white wires under the seat 3 See Figure 22 Obtain a sealed splice connector 3 from the kit See Figure 7 the two into one splice configuration Splice the heated hand grip wire harness power lead to the cut orange white wires per the instructions in the service manual appendix 4 Proceed to For ALL models in this section 2004 2010 Softail Models The heated hand grip switched power source is an open fuse position on the fuse panel See the FUSES section of the ser vice manual and the correct wiring diagram in the service manual appendix 1 Remove the fuse block cover Remove the two hex head screws fastening the fuse block bracket Pull the bracket and fuse block assembly away from the vehicle frame 2 Press the tab retaining the left fuse block and slide the block out of the mounting slots 3 See Figure 22 Obtain the orange white fuse block adapter wire 9 from the kit Note the terminal on each end see Figure 8 Only the terminal with the spring tabs will fit into this fuse block Carefully cut the unused terminal from the wire and discard it 4 See Figure 10 Locate the fuse cavity 1 indicate
15. cMOTOR HARLEY DAVIDSON WY J02983 INSTRUCTIONS REV 2015 03 26 HEATED HAND GRIP KITS GENERAL Kit Numbers 56047 03C 56107 03B 56174 03C 56196 03C 56512 02C 56619 03B 56694 04A 56750 04B 56822 03A 56825 03A 56828 03B 56923 05 56926 05A 56997 07A 56100030 56100111 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 Each kit contains one pair of heated hand grips plus the con necting parts see Figure 22 and Table 1 These Heated Hand Grip Kits are not compatible with internally wired handlebars Additional Parts Required 2011 later Softail models 2012 later Dyna models and 2014 later Sportster models require separate purchase of an Electrical Connection Harness H D Part No 72673 11 Tools and Supplies Required An UltraTorch UT 100 HD 39969 Robinair Heat Gun HD 25070 with Heatshrink Attachment HD 41183 or other suit able radiant heating device is required for the proper installation of this kit Installation of this kit requires the use of a terminal crimping tool and other parts and supplies Electrical Contact Lube H D Part No 99861 02 or equivalent is required after battery cable disconnection These items are available from a Harley Davidson dealer J02983 amp Many Harley Davidson Parts amp Accessories are made of plastics and metals which can be recycled
16. d as P amp A IGN on the fuse block cover in the right fuse block There should be a wire feeding one side of this circuit but no mating wire or fuse will be present Insert the terminal on the orange white adapter wire until it stops Refer to a nearby factory installed terminal for comparison to verify proper orientation and depth 5 Cut the excess length from the orange white power lead of the heated hand grip wire harness to within easy reach of the adapter wire 6 See Figure 22 Obtain a sealed splice connector 3 from the kit See Figure 7 the one into one splice configuration Splice the heated hand grip wire harness power lead to the adapter wire per the instructions in the service manual appendix 7 See Figure 22 Install the 2A fuse 12 from the kit into the P amp A IGN fuse cavity to complete the circuit 8 Slide the fuse block into the mounting slots in the fuse block bracket until it clicks firmly into place Install the bracket and fuse block assembly into position and fasten with the two hex head screws removed earlier Tighten securely 9 Proceed to For ALL models in this section J02983 is06516 ey e eh ee ee oh eo eh ey ee Po y Figure 10 P amp A IGN Fuse Block Cavity 2004 2010 Softail 2013 Earlier Sportster Models The heated h
17. e Figure 22 Use cable straps 8 from the kit to fasten the heated hand grip wiring to the wire harnesses along the vehicle frame 3 of 14 HARNESS CONNECTION GENERAL Splicing of wire leads is necessary in the installation of the heated hand grips to the motorcycle Find the instructions for a specific model in the sections that follow Refer to the service manual appendix for proper wire splicing procedures AWARNING 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 component Extreme heat can cause fuel ignition explosion resulting in death or serious injury e Avoid directing heat toward any electrical system com ponent other than the connectors on which heat shrink work is being performed e Always keep hands away from tool tip area and heat shrink attachment For 2011 and later Softail models See the next section For ALL OTHER models Proceed to BLACK LEAD CON NECTION for the specific model HARNESS CONNECTION 2011 LATER SOFTAIL MODELS 2012 LATER DYNA MODELS AND 2014 LATER SPORTSTER MODELS NOTE Requires separate purchase of an Electrical Connection Har ness H D Part No 72673 11 1 Locate the Digital Technician connector 91A a gray six way Deutsch pin connector with
18. explosion which could result in death or serious injury 00049a 1 If the negative battery cable WAS NOT disconnected at the beginning of the installation refer to the service manual to remove the seat and disconnect the negative black battery cable from the negative battery terminal Retain all seat mounting hardware 2 Refer to the service manual to disconnect the positive battery cable Remove the battery NOTE The black wire must remain long enough so the battery fits into the battery well without stressing or stretching the wire 3 See Figure 5 Cut the black wire on the heated hand grip wire harness to easily reach the ground stud 2 located below the circuit breaker in the battery well under the seat 4 Select the correct ring terminal 4 5 or 6 from the kit to fit the ground stud 5 of 14 1 Circuit breaker silver terminal red wire 2 Ground terminal black wire Figure 5 Connections with battery removed 2003 or Earlier Touring Models 2003 FLHTCU shown 5 Crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix 6 Install the ring terminal to the ground stud Secure per the torque specification in the service manual 7 Proceed to For ALL models in this section 2004 2007 Touring Models 1 Locate the main harness chassis ground stud there are two under the seat in front of the battery 2 Remove the nut from
19. h could result in equipment damage 00370a 5 Install the red wire ring terminal onto the threads of the circuit breaker silver terminal stud and tighten to 20 35 in Ibs 2 3 4 0 Nm 6 Proceed to For ALL models in this section 1 Rear splash guard 2 Fuse box Figure 17 Splash Guard 2003 or Earlier Softail Models 2003 Model Shown 1 Fuse box 2 Circuit breaker silver terminal red wire Figure 18 Circuit Breaker 2003 or Earlier Softails J02983 2003 Earlier Sportster Models The heated hand grip battery power source is the silver ter minal of the circuit breaker inside the electrical side cover See Figure 19 and Figure 11 1 See Figure 22 Select the correct ring terminal 4 5 or 6 from the kit to fit the silver terminal stud with the red wire on the circuit breaker 2 Cut the excess length from the heated hand grip harness red wire but DO NOT cut off the in line fuse holder Crimp the ring terminal to the end of the red wire per the Packard crimping tool instructions in the service manual appendix NOTICE The power wire red from the heated handgrip wire har ness must connect to the circuit breaker silver terminal Connecting to the circuit breaker copper terminal can cause circuit overload which could result in equipment damage 00370a 3 Install the red wire ring terminal onto the threads of the circuit breaker silver terminal stud and tighten to 20 35
20. he connector and wire from the heated hand grip throttle sleeve into the right side of the handlebar all the way through and out the left side of the handlebar 4 Install the heated hand grip throttle sleeve throttle cables and switch housing onto the right side of the handlebar per service manual procedures 5 Remove the black ring from the inboard end of the left side heated hand grip 1 Insert the connector from the right side hand grip into the left side grip connector 6 Use a strip of masking tape or grease pencil to mark the handlebar 4 3 4 in 120 mm from the left end AWARNING Do not lubricate left handlebar grip before installation Lubricating grip can cause it to come off while riding which could result in loss of control and death or serious injury 00315a NOTES Thoroughly clean handlebar to remove all residual adhesive If the handlebar grips are patterned align the pattern on the left grip with the pattern on the right grip while the throttle is in the fully closed position 7 Ifa large amount of wiring from the left side hand grip extends from the left end of the handlebar use a blunt flexible object such as a narrow rubber hose in one hand to gently feed the wire into the handlebar while using your other hand to ease the grip into position near the end of the handlebar 8 Remove the flexible object from inside the handlebar and carefully slide the left side grip onto the handlebar taking care n
21. hers securing the left side handlebar clamp to the clutch lever bracket Remove upper and lower switch housing screws a Remove the left side handlebar grip If the grip is the glued on type carefully cut it away from the handlebar using a sharp blade or knife 6 If equipped with a handlebar cover riser cover or outer fairing refer to the service manual and remove if neces sary to access the wire path through the upper fork clamp 2 of 14 HEATED HAND GRIP INSTALLATION 1 See Figure 22 and Table 1 Determine if the wire harness extension 7 is required for this installation e Hold the right side heated hand grip throttle sleeve and wire harness in position along the outside of the handlebar as if the assembly were installed on the handlebar The connector at the end of the wire harness on the hand grip sleeve must extend past the left end of the handlebar e If the connector extends past the opposite end of the handlebar the extension can be discarded e Ifthe connector does not extend past the opposite end of the handlebar connect the extension to the end of the right side hand grip wire harness NOTE Air pressure or an electrician s fish tape can be used to thread the wire harness completely through the handlebar If using a fish tape hook the end of the fish tape to the con nector and tape securely 2 Remove any wire retaining clips fastening the handlebar switch harness to the handlebar 3 Thread t
22. in lbs 2 3 4 0 Nm 4 Proceed to For ALL models in this section 1 Circuit breaker silver terminal red wire Figure 19 Circuit Breaker 2003 or Earlier Sportsters 2003 Earlier Touring Models The heated hand grip battery power source is the silver ter minal of the circuit breaker in the battery well under the seat 1 See Figure 5 Route the heated hand grip red wire to the silver terminal stud 1 of the circuit breaker located in the battery well under the seat 2 See Figure 22 Select the correct ring terminal 4 5 or 6 from the kit to fit the silver terminal stud with the red wire on the circuit breaker 3 Cut the excess length from the heated hand grip harness red wire but DO NOT cut off the in line fuse holder Crimp the ring terminal to the end of the red wire per the Packard crimping tool instructions in the service manual appendix 11 of 14 NOTICE The power wire red from the heated handgrip wire har ness must connect to the circuit breaker silver terminal Connecting to the circuit breaker copper terminal can cause circuit overload which could result in equipment damage 00370a 4 Install the red wire ring terminal onto the threads of the circuit breaker silver terminal stud and tighten to 20 35 in Ibs 2 3 4 0 Nm 5 Install the battery back into the vehicle but DO NOT con nect the battery terminals at this time 6 Proceed to For ALL models in this section 2004 201
23. minal on the orange white adapter wire until it stops Refer to a nearby factory installed terminal for comparison to verify proper orientation and depth 5 Cut the excess length from the orange white power lead of the heated hand grip wire harness to within easy reach of the adapter wire 6 See Figure 22 Obtain a sealed splice connector 3 from the kit See Figure 7 the one into one splice configuration Splice the heated hand grip wire harness power lead to the adapter wire per the instructions in the service manual appendix 7 See Figure 22 Install the 2A fuse 12 from the kit into the OPEN fuse cavity to complete the circuit 8 Install the electrical panel per the instructions in the service manual Install the electrical panel cover by aligning the pins with the rubber bushings in the electrical panel and pushing firmly into place 9 Proceed to For ALL models in this section is02589 1 CUT this terminal from wire 2 LEAVE this terminal on wire 3 Spring tabs 2 Figure 8 Fuse Block Adapter Wire Dyna and Softail is06515 ag og Ce ag be Nod C Figure 9 OPEN Fuse Block Cavity 2004 and Later Dyna 2003 Earlier Softail Models The heated hand grip switched power source is the orange white O W wire in the tail lamp h
24. o within easy reach of the cut orange white wires inside the side cover 8 of 14 3 See Figure 22 Obtain a sealed splice connector 3 from will be present Remove the three fuses 2 currently the kit installed in this row noting their location See Figure 7 the two into one splice configuration Splice Gently remove the orange plastic secondary lock from the the heated hand grip wire harness power lead to the main fuse block Insert the terminal on the orange white adapter harness orange white wires per the instructions in the wire until it stops Refer to a nearby factory installed ter service manual appendix minal for comparison to verify proper orientation and depth 4 Proceed to For ALL models in this section Install the secondary lock isO1116 1 Fuse box harness orange white wire Figure 12 Fuse Box Harness Behind Left Hand Side Cover 2003 or Earlier Touring Models FLHTCUI Shown 2004 2007 Touring Models The heated hand grip switched power source is an open fuse position on the fuse panel See the FUSES section of the ser vice manual and the correct wiring diagram in the service manual appendix 1 For 2004 2006 models Remove the left side cover per service manual instructions to access the fuse box For 2007 models Remove the right side cover per service manual instructions to access the fuse box For ALL models Remove the main fuse holder fuse block and dust cover from the vehicle per
25. ot to crush pinch or otherwise damage the wiring inside the handlebar Push the grip onto the handlebar up to the marking from Step 6 J02983 9 See Figure 1 Position the left side grip on the handlebar so the retaining flange 1 can be securely installed into the lower switch housing 2 is01100 1 Retaining flange 2 Route hand grip main harness outside and under the switch housing Figure 1 Heated Hand Grip Left Side NOTICE Do not route the handgrip main harness inside the switch housing Wires routed inside the switch housing could result in short circuits and equipment damage 00369a 10 Route the heated hand grip main wire harness beneath the switch housing 2 11 See Figure 22 If there are holes on the left underside of the handlebar install wire retainer clips 11 from the kit in the holes Fasten the wire harness to the clips If no holes use cable straps 8 to fasten the wire harness to the handlebar 12 Fasten the switch housing to the hand grip and handlebar per service manual instructions 13 Follow the existing wiring to route the heated hand grip main wire harness a through across or around the upper fork clamp b along the motorcycle frame to a general location under the seat For 2006 and later VRSC models only Route the black wire near the battery negative terminal For all VRSC models Route the red wire near the battery positive terminal 14 Se
26. red wire ring terminal onto the threads of the circuit breaker silver terminal stud and tighten to 20 35 in lbs 2 3 4 0 Nm 5 Proceed to For ALL models in this section 1 Circuit breaker silver terminal red wire Figure 16 Dyna Connections 2003 and Earlier Models Bottom View with Left Side Cover Removed 2003 Earlier Softail Models The heated hand grip battery power source is the silver ter minal of the circuit breaker located near the front of the rear fender splash guard below the seat 10 of 14 1 See Figure 17 Remove the rear fender splash guard 1 per the instructions in the service manual 2 See Figure 18 Route the heated hand grip wire harness red wire through the right side top of the frame under the seat and to the circuit breaker located near the front of the rear fender splash guard below the seat 3 See Figure 22 Select the correct ring terminal 4 5 or 6 from the kit to fit the silver terminal stud with the red wire on the circuit breaker 4 Cut the excess length from the heated hand grip harness red wire but DO NOT cut off the in line fuse holder Crimp the ring terminal to the end of the red wire per the Packard crimping tool instructions in the service manual appendix NOTICE The power wire red from the heated handgrip wire har ness must connect to the circuit breaker silver terminal Connecting to the circuit breaker copper terminal can cause circuit overload whic
27. s black wire connects directly to the battery negative terminal 1 Select the correct ring terminal 4 5 or 6 from the kit to fit the negative terminal fastener on the battery 2 Cut the heated hand grip harness black wire to within easy reach of the battery negative terminal Crimp the ring terminal to the end of the black wire per the Packard crimping tool instructions in the service manual appendix 3 Fasten the black wire ring terminal to the negative terminal mounting post on the battery Tighten the terminal fastener to 60 96 in Ibs 7 10 Nm For ALL models Verify that there is sufficient slack in the black lead so that handlebar movement will not be restricted Proceed to the ORANGE WHITE LEAD CONNECTION section for the specific model 6 of 14 ORANGE WHITE LEAD CONNECTION TO SWITCHED POWER SOURCE Use the service manual wiring diagrams for a specific model and year vehicle to locate a power source that is fed through the ignition switch 2003 Earlier Dyna Models The heated hand grip switched power source is an orange white O W main harness power lead inside the elec trical side cover 1 Remove the electrical side cover on the left side near the battery 2 See Figure 2 Carefully slice open an area of the main harness wrap inside the side cover at an accessible point and cut an orange white main harness power lead 3 Cut the excess length from the orange white power lead of the heated hand grip
28. se wiring into protected areas under the seat Use cable straps to keep wires away from moving parts heat sources and pinch or chafe points 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 8 Refer to the service manual and follow instructions to close or install the seat TROUBLESHOOTING See Figure 21 for the heated hand grip schematic diagram Hand Grips Do Not Produce Heat 1 See Figure 1 Check for proper wire routing The hand grip main harness must be routed outside of the switch housing If the wires were routed internally disassemble the left side switch housing and inspect for pinched wires If wires are pinched replace the left side grip and repeat the installation process with the correct wire routing 2 Check the wire connections of the orange white red and black hand grip main wire harness wires If a connection is open or weak repair the connection Test the hand grips Otherwise go to Step 3 3 Open or remove the seat per service manual instructions 4 Start the motorcycle 5 Check for 12 Volts DC across the red and black wires of the hand grip main wire harness If 12 VDC is not present across the wires check the fuse in the wire harness and replace it if blown Otherwise replace the left grip and wire harness and test the hand grips
29. service manual instructions Obtain the orange white fuse block adapter wire 9 from the kit For 2004 through 2006 models Note the terminal on each end see Figure 13 upper view Only the terminal WITHOUT the spring tabs will fit into the fuse cavity Carefully cut the terminal WITH spring tabs from the wire and discard it For 2007 models Note the terminal on each end see Figure 13 lower view Only the terminal WITH the spring tabs will fit into the fuse cavity Carefully cut the terminal Install the secondary lock and three fuses removed in the previous steps See Figure 22 Cut the excess length from the orange white heated hand grip harness wire Using a sealed splice connector 3 from the kit splice that wire to the adapter wire installed in Step 4 Install the 2A fuse 12 from the kit into the fuse cavity marked P amp A IGN 2A MAX to complete the circuit Proceed to For ALL models in this section oS X is05512 4 2004 2006 i 2008 1 CUT this terminal from wire 2 LEAVE this terminal on wire 3 Spring tabs 2 Figure 13 Fuse Block Adapter Wire FL Touring is04587a N _P amp A IGN RADIO PWR STARTER 2 AMP MAX 10 AMP BRAKE SIREN RELAY BATTERY RADIO MEM 15 AMP RELAY ROAD KING P amp A ACCESSORIES CRUISNBRAKE 15 AMP 15 AMP 15AN HEADLAMPS IGN LIGHTS INSTRUMENS 15 AMP 15 AMP 15 AM
30. tery Figure 3 Power and Ground Connections Softail Models 2013 Earlier Sportster Models 1 Remove the electrical side cover on the left side near the battery 2 Route the heated hand grip wire harness through the top of the frame under the seat to the circuit breaker on the inside of the electrical side cover 3 See Figure 4 Remove the ground screw 1 located e under the seat on some 1996 2003 models or e near the swingarm on 1995 or earlier models and 1996 2003 models without a screw under the seat onthe engine near the starter on 2004 and later models 4 Select the correct ring terminal 4 5 or 6 from the kit to fit the ground screw 5 Cut the black wire on the heated hand grip wire harness to easily reach the ground location and crimp the ring terminal to the end of the wire per the Packard crimping tool instructions in the service manual appendix 6 Install the ring terminal onto the ground screw threads Fasten the ground screw at the original location and secure per the torque specification in the service manual 7 Proceed to For ALL models in this section J02983 is01103 wA MAO rs 1 Ground screws black wire Figure 4 Ground Connections Sportster Models 2003 Earlier Touring Models AWARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery
31. to battery terminals For ALL OTHER models Models with main fuse Refer to the service manual to install the main fuse Models with main circuit breaker EXCEPT Sportster Refer to the service manual and follow the instructions to attach the negative battery cable Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals Sportster models with main circuit breaker Refer to the service manual and follow the instructions to connect the negative battery cable at the engine crankcase 3 For V Rod models only Install the air box aluminum cover per service manual instructions For ALL OTHER models Install the fuel tank per service manual instructions 4 Install the handlebar cover riser cover or outer fairing if equipped per service manual instructions 12 of 14 NOTE To prevent battery drain the heated hand grips are designed to function only with the ignition switch ON The hand grips produce maximum heat with the engine at cruising rom The heat settings on the heated hand grip control dial range from 1 minimum to 6 maximum 5 With the ignition switch OFF dial the left grip to a number setting Check that the hand grips are not producing heat Dial the hand grip to the off position Turn ignition ON but do not start the motorcycle Check that the hand grips are not producing heat 6 Start the engine Check the hand grips at all settings for proper heating 7 Tuck loo
32. up to 2 8 A additional current from the electrical system Service Parts See Figure 22 and Table 1 1 of 14 Please dispose of materials responsibly REMOVAL Preparation NOTE For vehicles equipped with security siren Verify that the hands free fob is present e Turn ignition switch ON For VRSC models only Remove the air box aluminum cover per service manual instructions Refer to the service manual to remove the main fuse For EFI models EXCEPT VRSC WARNING To prevent spray of fuel purge system of high pressure fuel before supply line is disconnected Gasoline is extremely flammable and highly explosive which could result in death or serious injury 00275a Follow service manual to purge and disconnect fuel supply line For vehicles with main fuse 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 to remove the main fuse Remove and retain the seat and all mounting hardware For vehicles with main circuit breaker WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect negative battery cable before proceeding 00048a 1 Refer to the service manual to remove the seat and dis connect the negative black battery cable from the neg ative battery terminal Retain all seat mounting hardware For carbureted models
33. wire harness to within easy reach of the cut orange white wires inside the side cover 4 See Figure 22 Obtain a sealed splice connector 3 from the kit See Figure 7 the two into one splice configuration Splice the heated hand grip wire harness power lead to the main harness orange white wires per the instructions in the service manual appendix 5 Proceed to For ALL models in this section is02055a 1 1 into 1 splice 2 2into 1 splice 3 3into 1 splice Figure 7 Splice Configurations 2004 2011 Dyna Models The heated hand grip switched power source is an open fuse position on the fuse panel See the FUSES section of the ser vice manual and the correct wiring diagram in the service manual appendix 1 Remove the electrical side cover on the left side near the battery by firmly grasping both sides and pulling outward 2 Remove the electrical panel from the vehicle per service manual instructions 3 See Figure 22 Obtain the orange white fuse block adapter wire 9 from the kit Note the terminal on each end see Figure 8 Only the terminal with the spring tabs will fit into this fuse block Carefully cut the unused terminal from the wire and discard it J02983 4 See Figure 9 Locate the fuse cavity 1 indicated as OPEN on the fuse block cover in the right fuse block There should be a wire feeding one side of this circuit but no mating wire or fuse will be present Insert the ter
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