Multi-Fit Braided Throttle/Idle Cable Kits

J020152009-12-17

GENERAL

Kit Numbers

Models

The Multi-Fit Throttle/Idle Cable Kits are available in a variety of housing lengths, fitting angles and travel lengths. Shorter or longer lengths may be necessary when modifications (such as optional handlebars) have been made to the motorcycle. See the Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts catalog for length information.

Fitment "A" is designed to work with 2002 FLHRCI and FLHRI models equipped with FLHRSEI handlebar kit part number 56675-05.

Fitment "B" is designed to work with 1996 FLTCU, 1996-2001 FLHTCUI, and 1998-2001 FLTRI models.

Fitment "C" is designed to work with 2002-2007 FLHR/I, FLHRCI and 2004 and later FLHRS/I models.

Fitment "D" is designed to work with 2002-2007 FLHR/I, FLHT/I, FLHTC/I, FLHTCU/I and 2006-2007 FLHX/I 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 references service manual information. A service manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.

Kit Contents

See Figure 10 and Table 2.

Table 1. Kit Numbers

Stainless Steel Kit	Stainless Steel Fitment	Diamondback Kit	Diamond-Black Kit	Diamondback and Diamond-Black Fitment	Angle	Length in (cm)
56616-03	C	56809-05	55723-10	C	90^°	39.5 (100.3)
56719-03	C	56810-05	N/A	C		41.0 (104.1)
38677-02	A	N/A	N/A	N/A		42.5 (108.0)
N/A	N/A	55749-07	55770-10	C		43.5 (110.5)
56378-03	C	55750-07	55799-10	C		45.5 (115.6)
N/A	N/A	55751-07	N/A	C		47.5 (120.7)
N/A	N/A	55752-07	N/A	C		49.5 (125.7)
56775-04	D	38778-05	N/A	D	70^°	39.0 (99.1)
56457-00A	B	55733-07	N/A	D		41.0 (104.1)
56778-04	D	N/A	N/A	N/A		42.0 (106.7)
N/A	N/A	55734-07	N/A	D		43.0 (109.2)
N/A	N/A	55735-07	N/A	D		45.0 (114.3)
N/A	N/A	55736-07	N/A	D		47.0 (119.4)
N/A	N/A	55737-07	N/A	D		49.0 (124.5)

REMOVAL

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual.

NOTE

When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be installed in the same locations.

NOTICE

Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a)

See Figure 1. Place the cardboard insert between the brake lever and lever bracket.

1	Brake lever
2	5/32 inch (4 mm) cardboard insert
3	Brake lever bracket

Figure 1. Install Cardboard Insert

See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal.

1	Upper switch housing
2	Lower switch housing
3	Throttle cable adjuster
4	Idle cable adjuster
5	Adjuster jam nut

Figure 2. Handlebar Throttle Control

Remove the right upper and lower switch housing screws.

Loosen the upper screw securing the handlebar clamp to the master cylinder housing. Remove the lower clamp screw and flat washer.

NOTE

If possible, leave the friction shoe in place. The friction shoe is a loose-fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken.

See Figure 3. Remove the brass ferrules from the notches on the inboard side of the throttle control grip. Remove the ferrules from the cable end fittings.

1	Throttle cable
2	Idle cable
3	Brass ferrule
4	Notch

Figure 3. Throttle/Idle Control Cables

Pull the crimped inserts at the end of the throttle and idle control cable housings from the lower switch housing. For best results, use a rocking motion while pulling. Remove cables with retaining rings from switch housing. Apply a drop of light oil on the retaining ring, if necessary, to help in removal.

NOTE

If installing different handlebars, measure the change in distance that will be required from the end of the cable housing to the throttle grip. Compare this additional required length to the cables provided in the kit.

If the cables are more than 2.0 inches (51 mm) longer or more than 1.0 inch (25 mm) shorter than the above measured distance, see a Harley-Davidson dealer for the correct cable length.

WARNING

Install proper length throttle cables. Incorrect cable length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00396b)

Follow instructions in the applicable service manual and remove air cleaner and backplate.

NOTE

To perform the following, it may be necessary to raise the fuel tank to access cables in area of frame backbone. Follow instructions in applicable service manual to raise fuel tank.

Make note of the original cable routing before removal.

FL Models Equipped with Cruise Control or FL models that are "Cruise-ready": See Figure 4. Prior to removing cables at carburetor/induction module, locate the cruise control roll-off switch plumbed into the idle control cable on the right side of the vehicle. Push rubber boot on switch forward to access spade-type wire terminals. Remove both female spade-type terminals from spade contacts on cruise control roll-off switch.

10.

Remove cables at carburetor/induction module as follows: Carbureted Models: See Figure 5. Remove cable barrel ends from holes in throttle wheel and release cable housings from cable guides on carburetor cable bracket. Fuel-Injected Models: See Figure 6 and Figure 7. Remove idle and throttle control cables from integral cable guides cast at front of induction module. Pull cable barrels ends from holes in throttle wheel.

11.

Cut and discard cable straps securing cables to frame backbone. Cut cable strap securing cable to coil bracket, if equipped. Remove cables.

12.

On FL models: Release the cables from the J-clamp fastened to the right side of the frame backbone. Remove bolt, washer, P-clamp and locknut to release cables from the steering head, if equipped.

1	Throttle cable
2	Idle cable
3	Convoluted tubing
4	Female spade terminal
5	Cruise control roll-off (boot)

Figure 4. Throttle Cable Configuration for Models Equipped with Cruise Control (Right Side View)

1	Throttle cable guide
2	Idle cable guide
3	Spring
4	Cable barrel end
5	Throttle wheel
6	Throttle cam stop
7	Stop plate

Figure 5. Throttle Cable Assembly (Carbureted Models)

1	Idle cable guide
2	Throttle cable guide

Figure 6. Throttle Cable Assembly (Fuel Injected Models)

1	Throttle wheel
2	Idle cable barrel end
3	Throttle cable barrel end

Figure 7. Throttle Cable Assembly (Fuel Injected Models)

INSTALLATION

See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar.

NOTE

The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle housing cable.

NOTE

For assembly, apply a drop of light oil on the retaining rings of the crimped inserts.

See Figure 8. Push the throttle cable housing and retaining ring (2) into the switch housing (1) larger hole, located in front of the tension adjuster screw.

Push the idle cable housing and retaining ring into the switch housing smaller hole, located behind the tension adjuster screw.

Push the throttle and idle control cable housings into the lower switch housing until each snaps into place.

NOTE

For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and orient so the pin hole is over the point of the adjuster screw.

Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.125 in. (3.2 mm).

See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (item 3, Figure 10 ) onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip.

Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar.

Loosely fasten the upper and lower switch housing screws.

Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket.

10.

Align the holes in the handlebar clamp with those in the master cylinder housing and loosely fasten the lower screw and flat washer. Position for rider comfort. Beginning with the top screw, tighten the screws to 6.8–9 N·m (60–80 in-lbs).

NOTE

Always tighten the lower switch housing screw first so that any gap between the upper and lower housings is at the front of the switch assembly.

11.

Tighten the lower and upper switch housing screws to 4–5 N·m (35–45 in-lbs).

12.

Remove the cardboard insert between the brake lever and lever bracket.

13.

Refer to the CABLE ROUTING section. Route cables according to the applicable model. On FLHT, FLTR and FLTC models equipped with cruise control or FLHT/FLTR/FLTC models that are "Cruise-ready", go to step 13a. For FLHR/I/S/SI/CI models equipped with Cruise Control or FLHR/I/S/SI/CI models that are "Cruise-ready", perform steps a-b below, then proceed to step 14. Otherwise, go to step 14.

a. Refer to Figure 4. Straighten spade contacts of cruise roll-off switch if bowed or bent back. The contacts must be parallel and line up perpendicular to the idle cable.

b. Separate the cruise roll-off switch wires so that the ends are free to the point where they enter the wire harness conduit. Now route straight down inboard of both the idle and throttle cables.

1	Idle cable retaining ring
2	Throttle cable retaining ring
3	Lower switch housing

Figure 8. Install Cable to Switch Housing

Cable Routing

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)

Be sure cables are not pinched between the frame and/or forks.
Be sure clutch cables do not pull tight when handlebars are turned fully to left or right fork stops.
Be sure throttle/idle control cables do not pull tight when handlebars are turned fully to left or right fork stops.

FLHR, FLHRI, FLHRCI, FLHRS and FLHRSI Models

Remove headlight and right side of headlight nacelle.
See Figure 10. Install slit corrugated tubing (6) onto each cable along the length of cable that will be inside the headlight nacelle. Open the end of the tube with a finger, install the end of the tube on the cable, then push tube the rest of the way onto cable.
Route cables along rear side of handlebars, following the front brake line, into the headlight nacelle area.
Route cables in a radius through the nacelle the same way the stock cables were routed. Continue routing back along right side of frame backbone, under gas tank and down to induction module or carburetor. Capture cables in both of the J-clamps found along the frame backbone.
Clip cables together using cable retainer (8). Locate clip on section of cables between handlebar and headlight nacelle.

FLHT/FLHX and FLTR Models

For FLTR Models Only: Route the cables following the brake line along the handlebars, then through the retainer clip next to the speedometer/tachometer housing assembly. For FLHT/FLHX Models Only: Route the cables downward following the brake line to the inner fairing. Pass the cables through the inner fairing grommet, then loop them back along the right side of the steering head.

From the right side of the steering head, route the throttle and idle cables along the right side of the frame backbone. After passing through the J-clamp on the frame backbone, route the cables downward to the induction module.

Following completion of cable to Carburetor/Induction Module connection procedures, insert the tapered end of new cable strap between ignition coil and coil bracket welded to underside of frame backbone. When cable exits left side, raise both ends so that eye is centered above the frame backbone.

Verify that idle and throttle cables, wire bundles, wire harness and frame backbone are captured before mating cable strap ends. Tighten cable strap, but leave loose enough so that one finger can be inserted between strap and frame backbone. Do NOT over-tighten. Cut off excess cable strap material.

For FLHT/FLHX Models Only: See Figure 9. Remove short slit corrugated tubing (1) from the kit and add it around the plumbed front brake line.

1	Slit corrugated tubing

Figure 9. Front Brakeline Corrugated Covering

CABLE ADJUSTMENT

	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)
1.	Perform the cable adjustment procedure following the instructions in the service manual.

FINAL ASSEMBLY

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)

NOTE

Turn the handlebars fully to the left and right stops and check the following items:

Cables should not catch on headlamp hardware or pass in front of headlamp.
Cables should not catch on turn signal mounting hardware or turn signals.
Cables should not catch on fuel cap or fuel gauge.
Cables should not catch on speedometer or tachometer.
Be sure cables are not pinched between the frame and/or forks.
Be sure throttle/idle control cables do not pull tight when handlebars are turned fully to left or right fork stops.
Cables should return freely from full-open to full-closed.

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.	Connect battery cables, positive (+) cable first or install the main fuse (if removed).
	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/light key switch on and apply the brake lever to test operation of the brake lamp.

SERVICE PARTS

Figure 10. Service Parts: Throttle/Idle Cable Kit

Table 2. Service Parts Table

Item	Description (Quantity)	Part Number	Item	Description (Quantity)	Part Number
Kit Number 56457-00A (Fitment B)			Kit Numbers 56775-04, 56778-04, 38778-05, 55733-07, *55734-07, 55735-07, 55736-07, 55737-07 (Fitment D)**
1	Cable, throttle control braided	56484-00B	1	Cable, throttle control braided	Not sold
2	Cable, idle control braided	56485-00B	2	Cable, idle control braided	Not sold
3	Ferrule, brass (2)	56508-76	3	Ferrule, brass (2)	56508-76
4	Retainer, ring, throttle (0.269") (not shown)	11272	4	Strap, cable (not shown)	10065
5	Retainer, ring, idle (0.238") (not shown)	11271	5	Clip, conduit (not shown)	70514-01
			6	Tubing, slit corrugated (2)	Not sold
*Kit Number 38677-02 (Fitment A)**			7	Tubing, slit corrugated (short) (not shown)	Not sold
1	Cable, throttle control braided	56389-02	8	Retainer, throttle cable (not shown)	70385-01
2	Cable, idle control braided	56390-02	* Replacement throttle retainer ring (0.269 inch) is available as part number 12272 and idle retainer ring (0.238 inch) as part number 12271. Both can be purchased from a Harley-Davidson dealer.
3	Ferrule, brass (2)	56508-76

Kit Numbers 56616-03, 56719-03, 56809-05, 56810-05, 55749-07, 55750-07, 55751-07, 55752-07, 55723-10, 56378-03, *55770-10, 55799-10 (Fitment C)**
1	Cable, throttle control braided	Not sold
2	Cable, idle control braided	Not sold
3	Ferrule, brass (2)	56508-76
4	Strap, cable (not shown)	10065
5	Clip, conduit (not shown)	70514-01
6	Tubing, slit corrugated (2)	Not sold