FAT APE ACCESSORY HANDLEBAR KIT
J064762018-01-16
GENERAL
Kit Numbers
55800748, 55800749, 55800750, 55800751
Models
For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
Separate purchase of additional parts or accessories are required for proper installation of this handlebar kit. See a Harley-Davidson dealer, 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.
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.
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, remove main fuse before proceeding. (00251b)
NOTE
  • Vehicles WITH security siren: With security fob present, turn ignition switch ON. After system is disarmed, turn ignition switch OFF. See service manual and remove main fuse.
  • Vehicles WITHOUT security siren: See service manual and remove main fuse.
ORIGINAL HANDLEBAR REMOVAL
NOTE
Cover painted parts to protect finish.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
1.
Remove windshield, if equipped.
2.
NOTE
Record front brake line routing and orientation of banjo fittings before removal.
Disconnect and remove brake line. See service manual. Save banjo bolts, but discard sealing gaskets.
3.
NOTE
Record clutch cable routing before removal.
Models with mechanical clutch: Disconnect clutch cable from the clutch lever. See service manual.
a.
Separate upper and lower clutch cable.
4.
NOTE
Record clutch fluid line routing before removal.
Models with hydraulic clutch: Remove clutch fluid line. See service manual.
5.
Remove and discard any plastic wiring retainer clips and cable straps from handlebar wiring.
6.
Disconnect left and right handlebar wiring connectors from main harness.
7.
NOTE
Record wire color and position in each cavity of connector housings.
Refer to correct connector section in service manual appendix to remove wires from housings.
8.
Use tape to wrap wire terminals from each individual harness to make separate leaders. Wrap each leader tight enough to pass easily through handlebars.
9.
Remove front brake master cylinder and clutch lever assemblies from handlebar. If necessary, remove attached turn signal lamps and mirrors.
10.
Remove left handlebar switch housing and pull wire through handlebar.
11.
Remove right grip/throttle sleeve. See service manual.
12.
Remove twist grip sensor from handlebar.
13.
Remove right handlebar switch housing and pull wire through handlebar.
14.
If left side hand grip is not glued to handlebar: Remove end cap from hand grip, if present. Remove hand grip. Set aside for installation onto new handlebar.
15.
NOTE
If equipped with 1.25" handlebar save hardware and riser parts for later installation.
Remove stock handlebar from handlebar risers. See service manual.
HANDLEBAR RISERS
1.
Remove handlebar risers and cup washers. See service manual.
2.
Remove and discard spacers and bushings from upper fork bracket.
3.
NOTE
Smaller diameter of aluminum isolator fits inside upper fork bracket.
Install aluminum isolators from kit in riser mounting location.
4.
Install upper cup washers.
5.
NOTE
If not equipped with 1.25" handlebar risers, replace with correct handlebar riser kit.
Install lower cup washers and handlebar risers with mounting hardware. Do Not tighten.
NEW HANDLEBAR INTERNAL WIRING
1.
See Figure 1. Stagger pins (1) so they are not in the same locations along harness (2) bundle.
1Pins
2Wire harness
3Two pin heated hand grip harness (if equipped)
Figure 1. Pins and Wire Harness
2.
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.
3.
Install suitable pull cords.
a.
Feed one pull cord through hole near left end of handlebar.
b.
Feed one pull cord through hole near right end of handlebar and one through right end of handlebar tube.
c.
Extract ends of all pull cords through center hole.
4.
a.
Tie cord to wire harness.
b.
Wrap tape (2) over harness, cord, and pins. Tape should come to a taper (3) and be flexible to ease pulling through handlebar.
c.
Pull cord through handlebar to route wire bundle to proper exit point.
1Pull cord
2Taped wire harness
3Tapered end
Figure 2. Pull Cord and Wire Harness
5.
Apply a light coat of liquid soap, or all-purpose lubricant to the right side switch wire bundle.
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)
6.
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.
7.
Repeat Steps 4 through 6 with the TGS, 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
Figure 3. Switch Housing Wire Routing
8.
Remove the tape from the ends of the wire bundles.
9.
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 5. 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.
See Figure 4. Adjust handlebar angle. The uprights of the handlebar run roughly parallel to the front forks.
Figure 4. Handlebar Install Orientation (typical)
4.
NOTE
Handlebar clamps are manufactured with pads on one half of the top clamp that should be touching the riser when assembled. The fasteners closest to the pads must be tightened first.
With the handlebar centered and oriented, tighten the riser clamp fasteners. Tighten.
Torque: 16.3–21.7 N·m (12–16 ft-lbs)
5.
Tighten handlebar riser to upper fork bracket fasteners.
Torque: 81.3 N·m (60 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. Tighten.
Torque: 6.7–9 N·m (60–80 in-lbs)
4.
Tighten first the lower. Then tighten the upper switch housing screws. This leaves any gap in the switch housing at the front for best appearance. Tighten.
Torque: 4–5.1 N·m (35–45 in-lbs)
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. Tighten.
Torque: 6.7–9 N·m (60–80 in-lbs)
9.
Tighten first the lower. Then tighten the upper switch housing screws. Tighten.
Torque: 4–5.1 N·m (35–45 in-lbs)
10.
See service manual. Install proper length clutch cable (purchased separately) or clutch fluid line (purchased separately).
11.
See service manual. Bleed clutch control system, if equipped.
12.
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.
13.
See service manual. Bleed brakes.
ELECTRICAL RECONNECTION
  1. Follow routing noted in disassembly steps until handlebar control wires and turn signal wires reach the main vehicle harness switch and signal wire connector housings.
  2. Refer to the notes taken during installation. See service manual. Install pins into connector pin housings.
  3. 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.
  4. Refer to the notes taken during removal and the service manual and connect all harness connectors.
  5. See Figure 5. Install hole plugs (2) into the handlebar. Make sure to align the logo.
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 line/cable, 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/cable 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 main fuse.
1.
Refer to the service manual. Install main fuse.
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 5. Service Parts: Handlebar
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
55800748
1
12” Fat Ape Handlebar, chrome
Not sold separately
2
Aluminum isolator
55900011A
55800749
3
12” Fat Ape Handlebar, black
Not sold separately
2
Aluminum isolator
55900011A
55800750
4
16” Fat Ape Handlebar, chrome
Not sold separately
2
Aluminum isolator
55900011A
55800751
5
16” Fat Ape Handlebar, black
Not sold separately
2
Aluminum isolator
55900011A
Items mentioned in text.
A
Knurled pattern