1.00 INCH (25.4 MM) DIAMETER HANDLEBAR KITS
J044042016-08-22
GENERAL
Kit Numbers
56036-08, 55800589, 55800590, 55800591, 55800592
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
NOTE
Instructions are provided for installing Kits 56176-08 and 56184-08 with internal or external handlebar switch wiring.
Kit 56036-08 MUST be installed with internal handlebar switch wiring only.
Handlebars for Trike models CANNOT be installed with internal handlebar switch wires.
Heated hand grips CANNOT be used on handlebars with internal handlebar switch wires.
Additional Parts or Accessories Required
Separate purchase of additional parts or accessories is required for proper installation of this handlebar kit on this model motorcycle. 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.
Wiring of Kits 56176-08 and 56184-08 and all installations of kit 56036-08 require separate purchase of a Twist Grip Sensor Kit (H-D Part No. 32310-08).
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)
For models using the original equipment (OE) brake line, the two sealing gaskets found at each banjo fitting must be replaced. Refer to the parts catalog or see a Harley-Davidson dealer for the correct part numbers.
Motorcycles equipped with a glued left side hand grip requires a new grip, sold separately. Refer to the parts catalog for replacement OE hand grips.
FLHX Models require separate purchase of handlebar-mounted mirrors. If fairing-mounted mirrors are removed, separate purchase of two small (H-D Part No. 755) and two large (H-D Part No. 732) hole plugs is recommended.
Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips and handlebar-mounted mirrors (FLHX Models) that are available.
Tools and Supplies Required
Fresh, uncontaminated DOT 4 brake fluid from a sealed container is needed.
A long shank ball-end socket (Snap-on® FABL6E or equivalent) aids in the removal and installation of the radio or storage box.
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
See Figure 4 and Table 1.
REMOVAL
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
1.
Refer to the service manual and follow the instructions to remove the main fuse.
2.
Remove outer fairing. See the service manual.
3.
Remove the fairing cap. See the service manual.
4.
FLHX Models: Handlebar-mounted mirrors (purchased separately) are required for proper installation of this handlebar. Removal of the inner fairing may be required, refer to the service manual. If fairing-mounted mirrors are being removed: Install the two small black plugs and large black plugs (purchased separately) to plug the fairing mirror holes.
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.
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)
5.
Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual.
NOTE
Cover painted parts to protect finish.
6.
Models with Radio: Remove the radio. See the service manual. Models without Radio: Remove the storage box. See the service manual.
a.
The four socket head screws fastening the radio or storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws.
b.
Pull the radio or storage box forward to remove it from the opening in the inner fairing.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
7.
Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee.
8.
Note the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See the service manual.
9.
Remove the front brake line assembly.
NOTE
Refer to the parts catalog for this year and model for a replacement OE brake line assembly and clutch cable, if needed.
Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available.
10.
Remove the front brake master cylinder and clutch lever assemblies from the handlebar.
11.
Disconnect the clutch cable from the clutch lever. See the service manual. If the clutch cable is being replaced: Follow instructions in the service manual to disconnect the clutch cable from the side cover and remove the cable from the vehicle.
NOTE
Note the harness routing and location of connector clips and cable straps before disconnecting and removing wiring inside the fairing.
12.
Disconnect the handlebar control wiring from the gray sixteen-way and black twelve-way main harness connectors inside the fairing. Refer to the service manual.
13.
Remove and discard the cable straps that secure both switch harnesses to the handlebar.
14.
Remove the right side switch housing assembly and wire harness. Refer to the service manual.
15.
Remove the left side switch housing assembly and wire harness. Refer to the service manual.
16.
If the left side hand grip is not glued to the handlebar: Remove the end cap from the hand grip (if equipped). Remove the hand grip and set it aside for installation onto the new handlebar.
17.
Remove the end cap from the right-hand grip (if equipped). Remove the hand grip from the handlebar.
NOTE
The twist grip sensor in the right side of the handlebar has a seal cap that protects internal electrodes from dirt and moisture, and also serves as a throttle grip retainer.
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.
If the throttle grip is being replaced: Discard the throttle grip and proceed to Step 16.
If the throttle grip is not being replaced: After removing the grip, note if the seal cap is attached to the end of the twist grip sensor.
  • If the seal cap is attached to the sensor, proceed to Step 16.
  • If the seal cap is still fastened to the index pins inside the throttle grip, use a stiff piece of mechanic's wire to capture the seal cap and pull it free of the index pins.
If the new handlebar is to have internal handlebar switch wiring: The OE twist grip sensor must be replaced with a new sensor.
If the new handlebar is to have external handlebar switch wiring: If carefully removed, the OE twist grip sensor can be used with the new handlebar.
18.
Remove the OE twist grip sensor. Refer to the service manual.
19.
Remove the twist grip sensor and set aside for installation with the new handlebar (external handlebar wiring) or discard (internal handlebar wiring).
1Clamp screw (4)
2Upper clamp
3Handlebar
4Handlebar riser (2)
5Riser attaching screw (2)
Figure 1. Handlebar Clamp and Risers
20.
See Figure 1. Remove the screws (1) that fasten the handlebar upper clamp (2) to the risers (4). Remove the clamp. Remove the handlebar (3).
NOTE
Do not remove the wires from the Molex handlebar switch connector pin housings inside the fairing.
21.
Note the wire colors and positions in each cavity of the socket housings leading from the switches. Refer to the wiring diagram and the service manual. Remove the wires (with socket terminals) from the socket housings.
22.
If the new handlebar is to have external handlebar switch wiring: Proceed to External Handlebar Wiring. If the new handlebar is to have internal handlebar switch wiring: Use tape to wrap the wire terminal ends from each source to make separate leaders. Wrap each leader tight enough to enter the wire entrance hole at the handlebar switch location and pass easily through the new handlebar.
INSTALLATION
Internal Handlebar Wiring
NOTE
Kit 56036-08 MUST be installed with internal handlebar switch wiring only.
1.
Route the wires through the handlebars following the instructions in the service manual.
NOTE
Note the style and orientation of the grommets so they will install into the switch harness slots correctly when the wire harnesses have been pulled through.
2.
For Kit 56036-08: See Figure 4. Slide the full-flanged left side grommet (2), flange end first, onto the left side switch wire bundle, positioning the grommet close to the switch end. Slide the partial-flanged right side grommet (3), flange end first, onto the right side switch wire bundle, positioning the grommet close to the switch end, with the flange oriented toward the center of the handlebar.
NOTE
The twist grip sensor MUST be replaced with a new sensor (H-D Part No. 32310-08), sold separately.
3.
For ALL Kits: Obtain the Twist Grip Sensor Kit (purchased separately). Use tape to wrap the wire terminals on the ends of the twist grip sensor wires to make a single leader. Wrap the leader tight enough to pass easily through the new handlebar.
4.
Tie the end of the string from the right side handlebar end hole to the twist grip sensor wire bundle.
5.
Tie the end of the string from the right side switch wire hole to the right side switch wire bundle.
6.
Apply a light coat of liquid soap, window cleaner or all-purpose lubricant to the right side switch and twist grip sensor wire bundles.
WARNING
Wiring in the switch housings must be routed exactly as shown. Pinch points in the switch housings can short-circuit or sever wires, which could cause loss of control resulting in death or serious injury. (00415b)
7.
Gently feed the twist grip sensor wire bundle into the right side handlebar end. See Figure 2. Route the right side switch wire bundle through the switch housing as shown. Gently feed the wire bundle into the right side switch wire hole. Pull the bundles down through the new handlebar and toward the center of the bar, while fitting the index tabs on the twist grip sensor into the slots on the end of the handlebar. One index tab and slot are smaller than the other to aid in proper assembly.
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 bundles through the wire-exit hole at the bottom center of the handlebar.
WARNING
Grommets in each of the wiring holes in the handlebar must remain in position after routing the wiring through the handlebar. Operation without the grommets in place can damage wires, causing a short circuit which could result in death or serious injury. (00416d)
9.
Tie the end of the string from the left side switch wire hole to the left side switch wire bundle.
10.
If necessary, apply a light coat of liquid soap, window cleaner or all-purpose lubricant to the left side switch wire bundle.
11.
Route the left side switch wire bundle through the switch housing as shown in Figure 2 for the right side wiring. Gently feed the wire bundle into the left side switch wire hole. Pull the bundle down through the new handlebar and toward the center of the bar.
NOTE
Insert the right side grommet into the handlebar slot with the flange toward the center of the bar.
12.
For Kit 56036-08: See Figure 4. Insert the switch wire grommets (2 and 3) into place in the switch wire holes in the handlebar.
13.
For ALL Kits: Loosely fasten the brake lever and clutch lever clamps to the new handlebar.
14.
Loosely fasten the handlebar switch housings to the new handlebar.
15.
Remove the tape from the ends of the wire bundles.
16.
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. Proceed to Handlebar Installation.
1Upper switch housing screw
2Lower switch housing screw
3Pinch points
Figure 2. Switch Housing Wire Routing (Right Side Housing Shown)
External Handlebar Wiring
  1. Route the wires following the instructions in the service manual.
  2. Obtain the twist grip sensor jumper harness removed earlier. Tie the end of the string from the center wire slot to the small green jumper harness pin housing.
  3. If necessary, apply a light coat of liquid soap, window cleaner or all-purpose lubricant to the jumper harness.
  4. NOTE
    The external latch on the green jumper harness pin housing will break if the string is pulled too hard. Any damage will render the OE twist grip sensor jumper harness unusable.
  5. Gently pull the string out through the right side handlebar end until the green pin housing is exposed.
  6. Connect the green socket housing on the twist grip sensor to the green pin housing on the jumper harness.
  7. If necessary, apply a light coat of liquid soap, window cleaner or all-purpose lubricant to the twist grip sensor wire bundle.
  8. Gently feed the twist grip sensor wiring into the right side handlebar end. Carefully pull the wire bundle down through the new handlebar and toward the center of the bar, while fitting the index tabs on the twist grip sensor into the slots on the end of the handlebar. One index tab and slot are smaller than the other to aid in proper assembly.
  9. Pull the jumper harness out through the lower center wire exit slot in the handlebar.
  10. See Figure 4. Cut the rubber sleeve (4) into two equal lengths. Slide a section of the sleeve onto each of the switch wire bundles, over the flexible conduit, positioning the outboard edge of the sleeve against the inboard switch end.
  11. NOTE
    The flexible conduit covering the switch wires should extend into the switch housings. Position the rubber sleeves against the sides of the switch housings to protect switch wiring.
  12. To prevent the wiring being pinched by the brake lever or clutch lever clamps, push the rubber sleeve-encased portion of the switch harness into the wiring slot on the new handlebar, just beneath the handlebar surface. Hold the harness/rubber sleeve below the surface of the handlebar while loosely fastening the brake lever or clutch lever clamp to the handlebar.
  13. Repeat Step 10 at the opposite end of the handlebar.
  14. Loosely fasten the handlebar switch housings to the new handlebar.
Handlebar Installation
1.
Center the new handlebar on the risers. Verify that the knurled handlebar areas exposed on the outboard side of each riser are equal.
2.
Position the original handlebar upper clamp and loosely install with the clamp screws saved earlier.
NOTE
The handlebar upper clamp is designed to leave a gap between the clamp and riser to the rear of the handlebar when installed.
1Snug left front screw
2Snug right front screw
3Tighten left front screw
4Tighten right front screw
5Tighten right rear screw
6Tighten left rear screw
7Front of vehicle
8Original handlebar riser
9Handlebar
10Original upper handlebar clamp
Figure 3. Handlebar Clamp Screw Tightening Sequence
3.
See Figure 3. Snug, but do not fully tighten, only the front two upper clamp screws in the following sequence:
a.
First, snug the left front screw (1).
b.
Then, snug the right front screw (2).
4.
Refer to the notes made during the removal steps, and the wiring diagram and the service manual. Insert each socket terminal from the left side switch wire bundle into the correct cavity of the gray socket housing removed earlier.
5.
Insert each socket terminal from the right side switch wire bundle into the correct cavity of the black socket housing removed earlier.
6.
Connect the gray handlebar switch wire socket housing to the gray pin housing inside the nacelle. Connect the black handlebar switch wire socket housing to the black pin housing inside the fairing.
7.
If the new handlebar has external handlebar switch wiring: Proceed to Step 9. If the new handlebar has internal handlebar switch wiring: Obtain the PVC tubing and the six-way black Molex pin housing from the Twist Grip Sensor Kit (purchased separately). Install the tubing over ALL of the wires coming from the twist grip sensor.
8.
Insert each pin terminal from the twist grip sensor into the correct cavity of the pin housing: From the yellow conduit, From the black conduit, Position the PVC tubing installed in Step 7 in the area of the radio or storage box. The tubing is moved to the proper location at final assembly.
a.
Black wire to cavity 1
b.
White wire to cavity 2
c.
Red wire to cavity 3
d.
Black wire to cavity 4
e.
White wire to cavity 5
f.
Red wire to cavity 6
9.
Connect the six-way black Molex pin housing from the twist grip sensor to the black six-way socket housing inside the fairing.
NOTICE
Improperly aligned handlebars or components can contact the fuel tank when turned to the left or right. Contact with the fuel tank can cause cosmetic damage. (00372b)
10.
Slowly turn handlebar to full left lock and full right lock. If contact occurs and the handlebars are properly centered, raise the handlebar angle as necessary until proper clearance is attained.
NOTE
The upper handlebar clamp screws MUST be final-tightened in the following sequence to make sure that proper clamping is achieved.
11.
See Figure 3. Tighten the upper handlebar clamp screws as follows:
a.
Tighten the left side front screw (1) until the left side of the handlebar clamp contacts the front of the left side handlebar riser.
b.
Tighten the right side front screw (2) until the right side of the handlebar clamp contacts the front of the right side handlebar riser.
c.
Tighten the left side front screw (3) to 21.7–27.1 N·m (16–20 ft-lbs).
d.
Tighten the right side front screw (4) to 21.7–27.1 N·m (16–20 ft-lbs).
e.
Tighten the right side rear screw (5) to 21.7–27.1 N·m (16–20 ft-lbs).
f.
Tighten the left side rear screw (6) to 21.7–27.1 N·m (16–20 ft-lbs).
NOTE
There will be a slight gap between the upper clamps and the risers toward the rear of the handlebar after tightening.
12.
Install a new (purchased separately) or original handlebar grip on the left end of the new handlebar following the handlebar grip instruction sheet or the service manual. For vehicles equipped with external handlebar switch wiring and heated hand grips: Install the heated grip to the new handlebar following the instructions included with the heated grips.
13.
Adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort.
14.
First tighten the clutch-lever clamp screws. Second tighten the bottom clutch-lever clamp screws. Tighten screws to 8.1–12.2 N·m (72–108 in-lbs).
15.
First tighten the lower, second tighten the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs).
NOTE
If the handlebar grips are patterned, align the pattern on the right grip with the pattern on the left grip while the throttle is in the fully-closed position.
For vehicles equipped with external handlebar switch wiring and heated hand grips: Install the heated grip to the new handlebar following the instructions included with the grips.
16.
Install the new (purchased separately) or original right grip/throttle sleeve. Refer to the service manual.
17.
Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort. The brake master cylinder must be level.
NOTE
Tighten the top brake lever clamp screw before tightening the bottom screw.
18.
First tighten the top, second tighten the bottom brake lever clamp screws to 8.1–12.2 N·m (72–108 in-lbs).
NOTE
Tighten the lower switch housing screw before tightening the upper screw. This leaves any gap in the switch housing at the front for best appearance.
19.
First tighten the lower, second tighten the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs).
20.
Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing.
Final Assembly
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)
  1. Carefully inspect the new (sold separately) or existing front brake line or lines for damage or defects, and replace if damaged. Install following the instructions in the service manual or the instructions included with the brake lines.
  2. Bleed the brakes. See the service manual.
  3. Install the clutch cable to the clutch lever or install a new clutch cable (sold separately) following the instructions in the service manual.
  4. Models with Radio: Install the radio. See the service manual. Models without Radio: Install the storage box. See the service manual.
  5. Position the PVC tubing on the twist grip sensor wires (previously installed) to prevent chafing of the twist grip sensor wires against the heat sink fins on the radio (if equipped) and the sharp edges of the radio or storage box mounting bracket inside the fairing.
  6. Install the fairing cap. See the service manual.
  7. Install outer fairing. See the service manual.
  8. FLHX Models: Install handlebar-mounted mirrors following the 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 and brake lines do not pull tight when handlebars are turned fully to the left or right fork stops.
1.
Verify that the ignition switch is turned to OFF. Install main fuse. Refer to the service manual.
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
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: Handlebar Kits
Table 1. Service Parts, Handlebar Kits
Kit
Item
Description (Quantity)
Part Number
56036-08
1
Handlebar
Not sold separately
2
Handlebar grommet, left side (full-flange)
11403A
3
Handlebar grommet, right side (partial-flange)
11642
55800589
1
Handlebar
Not sold separately
55800590
1
Handlebar
Not sold separately
55800591
1
Handlebar
Not sold separately
55800592
1
Handlebar
Not sold separately
Items mentioned in text, but not included in kit:
A
Original equipment handlebar riser (2)
B
Original equipment upper handlebar clamp
C
Original equipment handlebar clamp screw (4)
Kit 32310-08 - Twist Grip Sensor Kit (Purchased Separately)
The Heated Hand Grip items below are not used with these Handlebar Kits, and can be discarded:
Socket housing, two-way
Secondary lock, two-way socket housing
Seal pin (plug) (2)
Pin housing, two-way
Secondary lock, two-way pin housing