Accessory Handlebar Kit
J055482015-08-27
GENERAL
Kit Numbers
55800103, 55800198, 55800430, 55800431
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
55800103, 55800198 for Dyna or Sportster. Dyna models only: isolators (included) must be installed. Sportster models do not use isolators.
55800430, 55800431 for Sportster only.
Additional Parts or Accessories Required
Separate purchase of additional parts or accessories are required for proper installation of this handlebar kit. See the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for this model.
WARNING
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)
The two sealing gaskets found at each banjo fitting must be replaced. Refer to the parts catalog for this year/model motorcycle or see a Harley-Davidson® dealer for the 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 original equipment (OE) hand grips.
  • Refer to the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) to see the selection of Genuine Motor Accessory hand grips that are available.
Tools and Supplies Required
Loctite® 271 Threadlocker and Sealant - Red (H-D Part No. 99671-97) is required for the proper installation of this kit.
Fresh, uncontaminated hydraulic brake fluid will be needed. Refer to the owner's manual or service manual for this year/model motorcycle to determine the correct brake fluid.
These items are available from a Harley-Davidson dealer.
ABS Models:
WARNING
The rider's safety depends upon the correct installation of this kit. Dealer installation is required for vehicles equipped with ABS brakes. Proper installation of this kit requires the use of special tools available only through a Harley-Davidson Dealer. An improperly serviced brake system can adversely affect brake performance, which could result in death or serious injury. (00578b)
Non-ABS Models:
WARNING
Rider and passenger safety depend 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. (00333b)
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Kit Contents
PREPARATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a)
WARNING
Disconnect negative (-) 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. (00049a)
1.
Disconnect negative battery cable. Retain all seat mounting hardware.
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)
2.
Loosen or remove the fuel tank. Refer to the service manual.
  • If able to access all harness and throttle cable connections. The fuel tank may be moved up and rearward without disconnecting the fuel line or cross-over.
  • Unless able to access these connections, remove the fuel tank. Set aside for later installation.
CAUTION
Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b)
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240d)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
NOTE
If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.
Cover nearby motorcycle surfaces with an H-D Service Cover or polyethylene protective sheet to help protect against damage to the finish caused by spillage or splash of DOT 4 brake fluid.
  1. Drain the brake fluid from the front brake reservoir and brake lines per the instructions in the service manual.
ORIGINAL HANDLEBAR REMOVAL
NOTE
Cover painted parts to protect finish.
Remove the windshield, if equipped.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
1.
Note the front brake line routing and the orientation of the banjo fittings. See the service manual. Disconnect and remove the brake line. Save the banjo bolts, but discard the sealing gaskets.
2.
See the service manual and disconnect the clutch cable from the clutch lever. Disconnect the clutch cable from the side cover. Remove the cable from the vehicle.
NOTE
Record wire routing and cable strap locations before removal.
2007 and later models use Molex connectors. 2006 and earlier vehicles use Deutsch connectors. Refer to the correct connector section in the service manual appendix for disconnection procedures.
3.
Remove and discard any plastic wiring retainer clips and cable straps retaining the handlebar control and turn signal wiring from the handlebars to the harness junction connectors. Refer to the correct connector section in the service manual appendix to disconnect the handlebar wiring.
NOTE
Before disconnecting the turn signal wiring, note the turn signal wire routing.
4.
Disconnect turn signal connectors.
NOTE
DO NOT remove the wires from the handlebar switch connector housings under the fuel tank.
DO NOT remove the wires from the Multilock connector housing under the fuel tank.
5.
Note the wire colors and positions in each cavity of the connector housings leading from the switches and from the turn signals. Refer to the correct connector section in the service manual appendix to remove the wires from the housings.
6.
Use tape to wrap the wire terminal ends from each individual harness to make separate leaders. Wrap each leader tight enough to enter the grommet hole and pass easily through the new handlebars.
7.
Remove the front brake master cylinder and clutch lever assemblies from the handlebar. Remove the attached turn signal lamps and mirrors, if needed.
8.
Pull the wire sheath and enclosed harnesses through the handlebars to free the handlebar controls and turn signal lamps. Set the handlebar control/turn signal lamp assemblies aside.
9.
Refer to the service manual for removal of the right side switch housing assembly and harness. Access the throttle cables.
10.
Refer to the service manual to disconnect the idle and throttle cables from the right grip/throttle sleeve assembly. Disconnect the idle and throttle cables from the induction module. Unless being replaced, remove the right grip/throttle sleeve and set it aside for installation to the new handlebar.
11.
Refer to the service manual for removal of the left side switch housing assembly and wire harness.
12.
If the left side hand grip is not glued to the handlebar: Remove the hand grip and set it aside for installation to the new handlebar, unless being replaced.
13.
See the service manual. Remove stock handlebar from the handlebar risers. Save hardware and riser parts for later installation.
14.
For Dyna models: Replace riser assembly isolators:
a.
Remove riser bolts and risers from the upper fork clamp. Discard rubber isolators. Retain spacers and bolts.
b.
Install four new isolators, spacers, risers and riser bolts to the upper fork clamp. Tighten bolts snugly.
c.
Verify that risers are properly aligned.
d.
Tighten riser bolts to 41–54 N·m (30–40 ft-lbs).
NEW HANDLEBAR INTERNAL WIRING
1.
2014-2015 Models with heated hand grip wiring: Cut and remove the unused heated hand grip two-pin connectors from both ends of the harness.
2.
Unless already done, remove any cable straps and plastic wiring retainer clips that secured the switch harnesses to the OE handlebar.
3.
In not already done, use tape to wrap the wire terminal ends from each source to make separate leaders. Wrap each leader tight enough to enter the grommet opening and pass easily through the new handlebar.
4.
Label each wire bundle (left or right) to help make sure that wires are routed properly.
NOTE
Guide strings (or thin wires) may aid in the routing of the wire bundles through the handlebar.
5.
See Figure 1. Stagger the pins (1) so they are not in the same locations along the harness (2). See Figure 2. String a suitable cord (1) through the handlebar. Tie the cord to the wire harness. Wrap tape (2) over the harness and pins. Tape should come to a taper (3) and be flexible to ease pulling through the handlebar. Pull the cord through the bar to route the wire bundle to the proper exit point.
1Pins
2Wire harness
3Two pin heated hand grip harness
Figure 1. Pins and Wire Harness
1Pull cord
2Taped wire harness
3Tapered end
Figure 2. Trim Rings and Adheasive
6.
Apply a light coat of liquid soap, window cleaner or all-purpose lubricant to the right side switch wire bundle.
7.
See Figure 3. With the handlebar placed on a smooth, soft surface, grip ends upward, gently feed the right side switch wire bundle into the opening on the underside of the new handlebar and toward the large opening in the center of the bar.
WARNING
Carefully pull the wires through hole in handlebar to prevent stripping the wires. Stripped wires can cause short circuits and damage vehicle electrical components, which could cause loss of vehicle control resulting in death or serious injury. (00418b)
8.
Pull the taped ends of the wire bundle through the exit opening in the center of the handlebar. Bring the switch housing into approximate final position. DO NOT fasten the switch housing to the handlebar now.
9.
Repeat Steps 4 through 6 with the left side switch wire bundle, and both turn signals, if needed.
1Center wiring hole
2Upper switch mounting screw
3Lower switch mounting screw
4Position inside switch edge pinch-point above wires and hole in handlebar
5Keep wires clear of pinch-points near threaded post
6Wiring access
7Access hole plug
Figure 3. Switch Housing Wire Routing
10.
Remove the tape from the ends of the wire bundles.
11.
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.
Handlebar Installation
NOTE
Typical handlebar orientation places the handlebar riser plane parallel to the front forks of the vehicle. State or local regulations may dictate handlebar height limits. Research and adjust accordingly.
1.
See Figure 4. Install the handlebar (1) to the riser base, routing the wire bundles down through the upper fork bracket.
2.
Seat the handlebar with the knurled areas (A) centered on the riser base. Install the riser clamp and clamp bolts, but do not fully tighten.
3.
All models except XL1200V: Adjust handlebar angle. The uprights of the handlebar run roughly parallel to the front forks. Model XL1200V: Adjust handlebar angle. The uprights of the handlebar are 15 degrees rearward of the front fork angle (45 degrees off vertical).
NOTE
If the speedo/tach is mounted at the riser clamp, then tighten the rear pair of riser screws first, then the front riser screw pair.
If the speedo/tach is not mounted at the riser clamp, then tighten the front pair of riser screws first, then the rear riser screw pair.
4.
With the handlebar centered and oriented, tighten the riser clamp fasteners to 16.3–21.7 N·m (12–16 ft-lbs).
Hand Control and Switch Wire Housing Installation
1.
See service manual. Install the new (purchased separately) throttle control cables and a new (purchased separately) or OE right grip/throttle sleeve assembly.
2.
Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort. The brake master cylinder must be horizontally level while the vehicle is on its jiffy stand, for brake bleeding.
3.
Tighten first the top. Then tighten the bottom brake lever clamp screws to 6.7–9 N·m (60–80 in-lbs).
4.
Tighten first the lower. Then tighten the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs). This leaves any gap in the switch housing at the front for best appearance.
5.
Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.
NOTE
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.
6.
Install a new (purchased separately) or OE handlebar grip on the left end of the new handlebar according to the handlebar grip instruction sheet or the service manual.
7.
See service manual. Adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort.
8.
Tighten first the top. Then tighten the bottom clutch lever clamp screws to 6.7–9 N·m (60–80 in-lbs).
9.
Tighten first the lower. Then tighten the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs).
10.
Refer to the service manual and follow the instructions to install a proper length clutch cable (purchased separately).
WARNING
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)
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a)
11.
Carefully inspect the new brake lines (purchased separately) for damage or defects, and replace if damaged. Install the brake line per service manual instructions or the instructions included with the brake lines.
12.
Bleed the brakes per the instructions in the service manual.
ELECTRICAL RECONNECTION
  1. Follow the routing noted in the disassembly steps until the handlebar control wires and turn signal wires reach the main vehicle harness switch and signal wire connector housings.
  2. NOTE
    2007 and later models use Molex connectors. 2006 and earlier vehicles use Deutsch connectors. Refer to the correct connector section in the service manual appendix for connection procedures.
  3. Refer to the notes taken during installation. See service manual. Install the pins into the connector pin housings.
  4. Install any required electrical extension harnesses (sold separately)for hand controls and/or front turn signal harnesses. Refer to the installation instructions for those kits.
  5. Refer to the notes taken during removal and the service manual and connect all harness connectors.
  6. See Figure 4. Install hole plugs (2) into the handlebar. Make sure to align the logo.
FINAL ASSEMBLY
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)
  1. See the service manual. Remove mirrors.
  2. Switch right and left mirrors. Install above hand controls. See the service manual.
  3. Install the fuel tank per instructions in the service manual.
SAFETY CHECK
WARNING
Be sure that steering is smooth and free without interference. Interference with steering could result in loss of vehicle control and death or serious injury. (00371a)
  • Verify wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops.
  • Lines must not catch on headlamp hardware or pass in front of headlamp.
  • Lines must not catch on turn signal mounting hardware or turn signals.
  • Lines must not catch on fuel cap.
  • Lines must not catch on speedometer.
  • Make sure that lines are not pinched between the frame and/or forks.
  • Make sure that clutch line does not pull tight when handlebar is turned fully to left or right fork stops.
  • Make sure control wires/jumpers do not pull tight when handlebars are turned fully to left or right fork stops.
NOTE
Verify that the ignition switch is in the OFF position before attaching the battery cables.
WARNING
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)
1.
Refer to the service manual and follow the instructions given to attach the battery cables (positive cable first). Apply a light coat of petroleum jelly or corrosion retardant material to battery terminals.
WARNING
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 switch to IGNITION, but do not start the motorcycle. Test all switches and lights for proper operation.
3.
Turn the handlebar to the left and right steering stops, testing the handlebar control functions at each stop.
4.
Apply the front brake hand lever to test operation of the brake lamp.
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)
5.
Refer to the service manual, and follow instructions to install the seat.
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 serious injury. (00390a)
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
SERVICE PARTS
Figure 4. Service Parts: Chizeled Handlebar
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
55800103
1
Handlebar
Not sold separately
2
Plug, black (2)
55900019
3
Isolator (4)
53156-86
55800198
1
Handlebar
Not sold separately
2
Plug, chrome (2)
55900042
3
Isolator (4)
53156-86
55800430
1
Handlebar
Not sold separately
2
Plug, chrome (2)
55900042
55800431
1
Handlebar
Not sold separately
2
Plug, black (2)
55900095
Items mentioned in text.
A
Knurled pattern