VRSCA REDUCED REACH HANDLEBAR KIT
J025412005-08-24
GENERAL
Kit Number
56533-02A
Models
This kit fits 2002 through 2005 VRSCA models.
Additional Parts Required
Table 1. Additional Parts Required
Description (Quantity) | Part Number |
|---|---|
Brake Line Kit | 45792-02 |
Turn Signal Relocation Kit | 57205-05 |
Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately. Refer to the Parts Catalog for replacement stock hand grips
Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available.
WARNINGRider 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
Table 2. Kit Contents
Description (Quantity) | Part Number |
|---|---|
Reduced Reach Handlebar Kit 56533-02A | |
| Not Sold Separately |
Brake Line Kit 45792-02 | |
| Not Sold Separately |
| Not Sold Separately |
| Not Sold Separately |
| 45249-97A |
| 41731-88A |
| 10065 |
Original Handlebar Removal
| 1. | Stand the motorcycle upright so the front brake master cylinder is level. | |||||||||||||||||||||||||||||||
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) | ||||||||||||||||||||||||||||||||
| 2. | Refer to the Service Manual, and follow the instructions given to remove the right-side cover and maxi-fuse. NOTE When the mirror is removed, the turn signal assembly will be retained only by the wire harness clipped to the handlebar. Ensure that the turn signal assembly is not damaged or does not scratch other parts of the vehicle when loosened. Cover the airbox cover, front fender and fork tube assemblies with clean shop towels to keep the finish from being scratched. | |||||||||||||||||||||||||||||||
| 3. | While holding the turn signal lock nut underneath the clutch lever/ master cylinder assembly, rotate the left-side rear view mirror stalk counterclockwise to remove the mirror from the vehicle. Save the mirror and lock washer for later installation. | 
Figure 1. Clutch Master Cylinder | ||||||||||||||||||||||||||||||
| 4. | See Figure 1. Using a T27 TORX® drive head, remove the screws (3) and flat washers (4) that retain the handlebar clamp (2) to the clutch master cylinder reservoir (1). | |||||||||||||||||||||||||||||||
| 5. | Carefully remove the clip holding the wiring harness to the left side of the handlebar, and set it aside for re-installation. | |||||||||||||||||||||||||||||||
| 6. | Refer to LEFT HANDLEBAR SWITCH in the Service Manual. Use a T25 TORX drive head to separate the upper and lower switch housings. | |||||||||||||||||||||||||||||||
| 7. | Use twist ties or another suitable method to secure the clutch lever/ master cylinder, upper and lower switch housings, and the turn signal assembly to the left-side fork tube. | |||||||||||||||||||||||||||||||
| 8. | 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. | |||||||||||||||||||||||||||||||
| 9. | See Figure 2. To free the lower end of the top handlebar cover, loosen the two mounting bolts (5) holding the headlamp bracket (2) to the upper triple clamp (4). NOTE See Figure 4. The bezel hook (1) holds the bottom of the bezel and the top cover to the lower handlebar cover, and can be damaged if forced during removal or installation. | 
Figure 2. Headlamp Assembly and Triple Clamp 
Figure 3. Handlebar Assembly  Figure 4. Instrument Bezel Hook | ||||||||||||||||||||||||||||||
| 10. | See Figure 3. Without removing the top handlebar cover (2), remove the fasteners (7) holding the top cover and instrument bezel (1) to the lower handlebar cover (6). Take care to avoid damaging the tab and hook at the bottom of the instrument bezel (see arrow). | |||||||||||||||||||||||||||||||
| 11. | From the headlamp bracket end of the top handlebar cover (2), gently tilt the cover and instrument bezel (1) up and back to remove the cover and bezel. NOTE The instrument bezel can remain snapped to the upper handlebar cover. | |||||||||||||||||||||||||||||||
| 12. | Squeeze the two release latches on the 12-place wiring harness connector [39B], and gently pull the connector from the instrument cluster (9). Remove the instrument cluster from the lower handlebar cover (6). | |||||||||||||||||||||||||||||||
| 13. | Remove the fasteners (3) securing the lower handlebar cover to the handlebars (8), and remove the lower cover. | |||||||||||||||||||||||||||||||
| 14. | Remove the right-side rear view mirror and the turn signal assembly from the front brake master cylinder reservoir. Save the mirror, lock washer and turn signal assembly for later installation. | |||||||||||||||||||||||||||||||
| 15. | See Figure 2. Remove the two mounting bolts (5), loosened earlier, that hold the headlamp bracket (2) to the upper triple clamp (4). | |||||||||||||||||||||||||||||||
| 16. | Follow the instructions included with the Turn Signal Relocation Kit (purchased separately) to re-install the turn signals to the triple clamp. | 
Figure 5. Master Cylinder Reservoir (Shown With Cover Removed) | ||||||||||||||||||||||||||||||
| 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) NOTICE Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) | ||||||||||||||||||||||||||||||||
| 17. | Refer to FRONT BRAKE MASTER CYLINDER/ RESERVOIR in the Service Manual, and follow the instructions to drain the brake fluid from the reservoir and lines. See Figure 5. Disconnect the front brake line at the reservoir. Save the banjo bolt (1), but discard the sealing washers (2). | |||||||||||||||||||||||||||||||
| 18. | See Figure 6. Remove the banjo bolt (2) and two sealing washers (3) to disconnect the brake line fitting from each brake caliper (4). Save the banjo bolt but discard the sealing washers. Allow the remaining fluid from the brake line to drain into the container. NOTE On dual disk systems, the left and right side brake lines are similar, but not identical. To distinguish between them, carefully mate the new brake lines up to the old brake lines
before removing the old lines from the motorcycle. Make sure the banjo fittings on the new brake lines are oriented in the same way as the ones on the old brake lines. See Figure 7. The brake line manifold (1) mounts to the underside of the lower fork bracket with the screw (2) forward of the brake lines. | 
Figure 6. Front Brake Components 
Figure 7. Front Brake Line Manifold | ||||||||||||||||||||||||||||||
| 19. | Carefully make note of the original brake line routing, then remove the brake lines from the motorcycle. Retain the screw. | |||||||||||||||||||||||||||||||
| 20. | Install the new braided brake line from the Brake Line Kit (purchased separately) into position. Tighten the screw (2) that secures the brake line manifold tee (1) to the fork stem to 1.5 Nm (14 in-lbs). See Figure 6. Tighten the brake line fittings (4) that thread into the brake line tee to 34 Nm (25 ft-lbs) . Adjust the brake lines to each side of the front wheel, but leave the assembly loosely in place for now. NOTE A small section of corrugated cardboard or the eyelet of an
ordinary cable strap can be used for this purpose. See Figure 8. | 
Figure 8. Protect Stoplight Switch | ||||||||||||||||||||||||||||||
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) | ||||||||||||||||||||||||||||||||
| 21. | Remove the two screws and flat washers that retain the handlebar clamp to the brake master cylinder reservoir. Remove the reservoir/ brake lever assembly from the handlebar, and set it aside in a clean location. | |||||||||||||||||||||||||||||||
| 22. | Carefully remove the clip holding the wiring harness to the right side of the handlebar, and set it aside for re-installation. | |||||||||||||||||||||||||||||||
| 23. | Refer to RIGHT HANDLEBAR SWITCH in the Service Manual. Use a T25 TORX drive head to separate the upper and lower switch housings. | |||||||||||||||||||||||||||||||
| 24. | Use twist ties or another suitable method to secure the upper and lower switch housings, and the turn signal assembly to the right-side fork tube. | |||||||||||||||||||||||||||||||
| 25. | Refer to THROTTLE CABLES: REMOVAL in the Service Manual, and disconnect the throttle cables from the right grip/ throttle sleeve assembly. Remove the right grip/ throttle sleeve assembly from the handlebar and set it aside for installation to the new handlebar. | |||||||||||||||||||||||||||||||
| 26. | See Figure 3. Remove the two hex flange head screws (5) holding the handlebars to the upper triple clamp (4). Remove and discard the handlebars, but save the screws. |
New Handlebar Installation
| 1. | Obtain the new Reduced Reach Handlebar from the kit. Refer to Figure 3. Mount the handlebar (8) on the upper triple clamp (4). Install and tighten the handlebar screws (5) removed earlier, and tighten to 41-47 Nm (31-35 ft-lbs). | |
| 2. | Mount the lower handlebar cover (6) to the handlebar with the fasteners (3) removed earlier. Tighten the fasteners to 6-10 Nm (54-88 in-lbs). | |
| 3. | Set the instrument cluster (9) into the handlebar bottom cover. Connect the wiring harness to the instrument cluster. Gently push the connector into the socket until the release latches lock into place. NOTE See Figure 4. The hook (1) holding the bottom of the bezel and the top cover to the lower handlebar cover can be damaged if forced during installation. | |
| 4. | See Figure 3. Orient the instrument bezel (1) and fit the bezel hook over the tab on the lower handlebar cover (6). Gently tilt the bezel and the top handlebar cover (2) until the bezel hook snaps into place. | |
| 5. | Fit the top cover (2) under the headlamp bracket. The bezel edge should fit snugly into the grooved rim of the lower and upper covers. | |
| 6. | Install the fasteners (7) that hold the top handlebar cover and instrument bezel, and capture the instrument cluster (9). Tighten the fasteners to 1.3-1.9 Nm (12-16 in-lbs). | |
| 7. | See Figure 2. Install the two mounting bolts (5) that hold the headlamp bracket (2). Tighten the bolts to 11-18 Nm (9-13 ft-lbs). | |
| 8. | Obtain a new left-side hand grip (purchased separately) or the "glueless design" grip saved earlier, and install onto the left side of the handlebar. | |
| 9. | Refer to LEFT HANDLEBAR SWITCH: INSTALLATION in the Service Manual, and follow the instructions given to: a. Use the T25 TORX drive head to install the upper and lower switch housings onto the handlebar. Do not fully tighten the screws. b. See Figure 1. Install the clutch master cylinder reservoir and lever assembly (1) and the handlebar clamp (2) to the handlebar with the T27 TORX® screws (3) and flat washers (4) removed earlier. Orient the lever for rider comfort and posture, and tighten first the top, then the bottom handlebar clamp screw to 8-9 Nm (71-80 in-lbs). c. Tighten first the lower, then the upper switch
housing screws to 4.0-5.1 Nm (35-45 in-lbs). NOTE Do not remove the 4mm (5/32 inch) thick insert (see Figure 8 until the right-side switch housing has been completely installed. Orient the brake lever for rider comfort and posture before torquing the screws | |
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) | ||
| 10. | Refer to RIGHT HANDLEBAR SWITCH: INSTALLATION in the Service Manual, and follow the instructions given to install the throttle control cables, right grip/ throttle sleeve assembly, upper and lower switch housings and brake master cylinder reservoir/ brake lever assembly. | |
| 11. | Obtain the clips saved earlier, and secure the left-side and right-side control wiring harnesses to the handlebar. | |
| 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) and brake line are clean and undamaged before assembly. (00323a) | ||
| 12. | See Figure 5. Obtain two new steel/ rubber washers from the kit. Using D.O.T. 5 brake fluid, lubricate the washers. Position the washers on each side of the hydraulic brake line fitting at the master cylinder reservoir. Thread the banjo bolt saved earlier through one washer, the brake line fitting, the second washer and into the master cylinder housing. Tighten the banjo bolt to 23-31 Nm (17-23 ft-lbs). | |
| 13. | See Figure 6. Obtain two new steel/ rubber washers from the kit, and lubricate with D.O.T. 5 brake fluid. Position the washers on each side of the hydraulic brake line fitting at the caliper. Thread the banjo bolt saved earlier through one washer, the brake line fitting, the second washer and into the caliper. Tighten the banjo bolt to 23-31 Nm (17-23 ft-lbs). Repeat this step for the opposite side. | |
| 14. | Refer to BLEEDING BRAKES in the Service Manual. Fill and bleed the front brake system. | |
| 15. | Refer to the Service Manual, and follow the instructions given to install the maxi-fuse and right side cover. |
Safety Check
| 1. | Check the handlebars, turn signal wiring and hydraulic lines for proper clearance. Re-check while moving handlebars from full left to full right (lock to lock) position. Adjust if necessary. | |
| 2. | Verify proper operation of the master cylinder relief port. Actuate the brake lever with the reservoir cover removed. A slight spurt of fluid will break the surface if all internal components are working properly. | |
| 3. | Install the gasket and cover on the reservoir. Tighten to 0.7-0.9 Nm (6-8 in-lbs). | |
| 4. | Install the rear view mirrors, using the lock washers saved earlier, and the chrome acorn nuts from the Turn Signal Relocation Kit. Adjust the mirror for proper field of vision and tighten the acorn nut to 16 Nm (12 ft-lbs). Check mirror adjustment and reposition if necessary. | |
| 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) | ||
| 5. | Turn the ignition ON. Pump the brake hand lever to verify operation of the brake lamp. | |
| 6. | Test ride the motorcycle. If brakes feel spongy, bleed the system again. |