0/0
LIGHTED HANDLEBAR END CAPS
J035642006-08-17
GENERAL
Kit Number
56870-06
Models
This kit fits all Harley-Davidson models that have large or medium Genuine Harley-Davidson Accessory hand grips with removable end caps. This kit is not compatible with models equipped with heated hand grips.
For models equipped with internally wired handlebars, it may be necessary to remove the handlebars and all of the electrical wiring inside to be installed later with the wiring from the kit.
Some models may require drilling holes in the handlebars. Refer to "Install Y-Harness and Route Cable Handlebar - Other Touring Models" in this Instruction Sheet.
Additional Parts Required
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.
NOTICE
It is possible to overload the vehicle's charging system by adding too many electrical accessories. If the combined electrical accessories operating at any one time consume more electrical current than the vehicle's charging system can produce, the electrical consumption can discharge the battery and cause damage to the vehicle's electrical system. (00211d)
Kit Contents
See Figure 23 and Table 4.
NOTE
Place a clean shop towel or a protective blanket over the equipment to avoid scratching painted surfaces when installing this kit.
This kit requires up to 60 mA additional current from the electrical system.
WARNING
When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (00310a)
REMOVAL
Prepare for Service
Touring Models: Remove left side saddlebag, left side cover, and maxi-fuse. Refer to SADDLEBAG and MAXI-FUSE in Service Manual.
Softail and Dyna Models:
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. Remove seat according to the instructions in the Service Manual.
  2. Disconnect battery cables, negative (-) cable first.
  3. Remove fuel tank according to the instructions in the Service Manual.
Sportster Models: Remove left side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
V-Rod Models: Remove right side cover and maxi-fuse. Refer to MAXI-FUSE in Service Manual.
Remove Existing Handlebar Components
1. See Figure 1. Remove screws from handlebar switch controls, brake lever mounting bracket, and clutch lever mounting bracket. Set the switch controls and brackets aside. See Service Manual for instructions.
2. Remove existing handlebar grips.
1Switch housing screws
2Grooves
3Handlebar clamp
4Left handlebar grip
5Larger diameter of flange
Figure 1. Left Handlebar Switch Housing
INSTALLATION
Install Y-Harness and Route Cable Through Handlebar - FLHR/C/S Touring Models
1. See Figure 2. Remove turn signal wire retaining clip (1) near the end of each side of the handlebars (2).
2. See Figure 23. Install one soft rubber grommet (8) ( Figure 2 , Item 3) from kit in each of the holes where retaining clips were removed.
1Retaining clip
2Left handlebar
3Insert grommet here
Figure 2. Replace Retaining Clip With Grommet
3. Remove headlamp assembly. Refer to HEADLAMP (FLHR/C/S) in Service Manual.
4. See Figure 3 and Table 1. Locate and separate front turn signal connector inside nacelle. Note wire color and cavity locations.
Figure 3. Front Turn Signal Connector (FLHR/C/S)
5. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
6. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
7. Insert combined Y-harness assembly between the two separated front turn signal connectors on vehicle.
8. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assembly (6) installed on bike.
9. Route wire harness cables along appropriate sides of handlebars to holes containing rubber grommets previously installed.
10. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
11. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
Table 1. Turn Signal Connectors
Model
Multilock
Connector
FLHR/C/S
2005-earlier FLHT/C/U
2002-earlier FLTR
2003-later FLTR
2006-later FLHX, FLHT/C/U
6-place
6-place
6-place
3-place
4-place
Softail
6-place
Dyna (2005-earlier)
Dyna (2006-later)
6-place
3-place
Sportster, VRSC, and Older Models
6-place
Table 2. Wire Color and Cavity Locations
Left and Right Turn Signals
Right Turn Signal
Cavity
1
2
3
6-Place Connector
Blk
Brn
Blue
Y-Harness
Blk
Red
Blue
Left Turn Signal
Cavity
4
5
6
6-Place Connector
Blue
Vio
Blk
Y-Harness
Blue
Red
Blk
1Connects to main harness
2Connects to turn signal harness
3Y-harness assembly (includes item 4)
4Fuse holder (2) (with 1 amp fuses, not shown)
5Socket housing on wire harness
6Pin housing on Y-harness
7Wire harness assembly
Figure 4. Y-Harness, Wire Harness, and Connections
Figure 5. Route Cable Out End of Handlebar
Install Y-Harness and Route Cable Through Handlebar - Other Touring Models
1. See Figure 6. Drill a 1/4 in. (6.4 mm) hole in the center of the recessed area of each side of the handlebar (2).
NOTE
It may be easier to use multiple smaller diameter bits until the 1/4 in. (6.4 mm) diameter is reached.
2. Remove burs from drilled hole.
1Drilled hole
2Handlebar
3Grommet
4Wire harness cable
Figure 6. Drill Hole in Handlebar and Insert Grommet
6-Place Multilock Connectors:
1. Remove outer fairing. Refer to UPPER FAIRING/WINDSHIELD in Service Manual.
2. See Figure 7 and Table 1. Locate and separate front turn signal connector inside inner fairing - left fairing support brace. Note wire color and cavity locations.
Figure 7. Front Turn Signal Connector (2005-Earlier FLHT/C/U)
3. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
4. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
5. Insert combined Y-harness assembly between the two separated front turn signal connectors.
3 and 4-Place Multilock Connectors:
1. Remove outer fairing. Refer to UPPER FAIRING/WINDSHIELD in Service Manual.
2. See Figure 8 and Table 3. Locate and separate front turn signal connectors inside inner fairing - left and right fairing support brace. Note wire color and cavity locations.
1Left front turn signal connector
2Right front turn signal connector
Figure 8. Front Turn Signal Connectors (FLTR Shown)
3. See Figure 23. Locate appropriate connectors (3 or 4-place) and two Y-harness assemblies (5) from kit.
4. See Figure 9. Install appropriate connectors on ends of Y-harness assemblies. See Table 3. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
5. See Figure 9. For models with 4-place multilock connectors, install ends of jumper wire assembly (8) ( Figure 23 , Item 20) into open cavities in Y-harness connectors.
6. Insert Y-harness assemblies with connectors between the two separated front turn signal connectors on vehicle.
Table 3. Turn Signal Connections (3 and 4-Place)
Left Turn Signal
Right Turn Signal
Violet to Red
Brown to Red
Blue to Blue
Blue to Blue
Black to Black
Black to Black
Gray/Black to Gray/Black
4-Place Only
Gray/Black to Gray/Black
4-Place Only
1Connects to main harness
2Connects to turn signal harness
3Y-harness assembly (includes item 4)
4Fuse holder (2) (with 1 amp fuses)
5Socket housing on wire harness
6Pin housing on Y-harness
7Wire harness assembly
8Jumper wire assembly (4-place only)
Figure 9. Y-Harness, Wire Harness, and Connections
All Multilock Connectors
  1. See Figure 4. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assemblies (6) installed on bike.
  2. Route wire harness cables along same route as turn signal wires to exit fairing. Then route cables along appropriate sides of handlebars to previously drilled holes in Figure 6.
  3. See Figure 23. Place one hard grommet (21) from kit over the end of each wire harness and slide over cable.
  4. See Figure 6. Insert ends of wire harness cables into respective previously drilled holes, and feed cables through handlebars until they come out the ends of handlebars approximately 4 in. (101.6 mm).
  5. Press nylon grommet (3) into handlebar (2) and orient grommet flange along length of recess in handlebar.
  6. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
Install Y-Harness and Route Cable Through Handlebar - Softail Models
1. See Figure 2. Remove turn signal wire retaining clip (1) near the end of each side of the handlebars (2).
2. See Figure 23. Install one soft rubber grommet (8) ( Figure 2 , Item 3) from kit in each of the holes where retaining clips were removed.
3. Remove fuel tank. Refer to FUEL TANK: CARBURETED or FUEL TANK: EFI in Service Manual.
4. See Figure 10 and Table 1. Locate and separate front turn signal connector under fuel tank on right side. Note wire color and cavity locations.
Figure 10. Softail Front Turn Signal Connector
5. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
6. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
7. Insert combined Y-harness assembly between the two separated front turn signal connectors on vehicle.
8. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assembly (6) installed on bike.
9. Route wire harness cables underneath fuel tank and along appropriate sides of handlebars to holes containing rubber grommets previously installed.
10. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
11. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
Install Y-Harness and Route Cable Through Handlebar - Dyna Models
All Dyna Models
  1. See Figure 2. Remove turn signal wire retaining clip (1) near the end of each side of the handlebars (2).
  2. See Figure 23. Install one soft rubber grommet (8) ( Figure 2 , Item 3) from kit in each of the holes where retaining clips were removed.
2005-Earlier Models
1. See Figure 11 and Figure 12. Remove plug on right side of top frame tube. At service loop, remove cable strap and push wire harness into top frame tube. Pull front turn signal connector out from hole on right side of tube.
2. Separate front turn signal connectors. Note wire color and cavity locations.
3. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
4. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
5. Insert combined Y-harness assembly between the two separated front turn signal connectors on vehicle.
6. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assembly (6) installed on bike.
7. Route wire harness cables inside top frame tube (under fuel tank) and along appropriate sides of handlebars to holes containing rubber grommets previously installed.
8. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
9. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
1Cable strap
2Wire harness
Figure 11. Dyna Service Loop (2005-Earlier)
1Frame tube
2Plug
Figure 12. Dyna Top Frame Tube (2005-Earlier)
1Frame tube
2Cover
3Plug
Figure 13. Dyna Top Frame Tube (2006-Later)
2006-Later Models (Except FXDWG)
  1. See Figure 13. Remove cover under top frame tube, then pull front turn signal connectors (3-place multilock) out from opening under tube.
  2. Separate front turn signal connectors. Note wire color and cavity locations.
  3. See Figure 23. Locate 3-place multilock connectors (14, 15) and two Y-harness assemblies (3) from kit.
  4. See Figure 9. Install connectors on ends of Y-harness assemblies. See Table 3. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
  5. Insert Y-harness assemblies with connectors between the two separated front turn signal connectors on vehicle.
  6. See Figure 4. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assemblies (6) installed on bike.
  7. Route wire harness cables inside top frame tube (under fuel tank) and along appropriate sides of handlebars to holes containing rubber grommets previously installed.
  8. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
  9. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
2006-Later FXDWG Models
1. See Figure 23. Locate two wire harness assemblies (19) from kit and remove 3-place connectors from ends of harness. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
2. Disconnect handlebar control wiring connectors from main harness. Refer to DEUTSCH ELECTRICAL CONNECTORS in Service Manual.
NOTE
Do not remove the pin (male) terminal wires from the Deutsch connectors wired to the main harness under the fuel tank.
3. Remove handlebar following the instructions in the Service Manual.
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)
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)
4. Wire handlebar as follows:
a. See Figure 14. Route right-side wire bundle through switch housing.
b. Repeat for left side switch housing wire bundle.
c. Loosely fasten handlebar switch housings to handlebar.
d. Remove tape from ends of wire bundles.
e. Test for electrical continuity between each wire and handlebar. If continuity is indicated, inspect wire routing through the handlebars and switch housing for a short circuit.
Figure 14. Switch Housing Wire Routing (Right Side)
5. Combine terminated ends of wire harness cables from kit with appropriate handlebar wire bundles for left and right switch housings. Wrap loose socket-terminals of separate wire bundles with tape.
6. See Figure 15. Gently feed wire bundle into right side of handlebar toward center of bar. Pull taped end of wire bundle through exit hole.
7. Reconnect handlebar control wiring connects from main harness. Refer to DEUTSCH ELECTRICAL CONNECTORS in Service Manual.
8. See Figure 23. Reconnect 3-place connectors removed earlier from wire harness assemblies (19).
9. Install handlebar following the instructions in the Service Manual.
10. See Figure 13. Remove cover under top frame tube, then pull turn signal connectors (3-place multilock) out from opening under tube.
11. Separate front turn signal connectors. Note wire color and cavity locations.
12. See Figure 23 and Table 3. Locate 3-place multilock connectors and two Y-harness assemblies (3) from kit.
13. Install connectors on ends of Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
Figure 15. Feed Wires Out Center of Handlebar
14. Insert Y-harness assemblies with connectors between the two separated front turn signal connectors.
15. See Figure 4. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assemblies (6) installed on bike.
16. Route wire harness cables inside top frame tube (under fuel tank) and along appropriate sides of handlebars to holes containing rubber grommets previously installed.
17. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
18. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
Install Y-Harness and Route Cable Through Handlebar - Sportster Models
1. See Figure 2. Remove turn signal wire retaining clip near the end of each side of the handlebars.
2. See Figure 23. Install one soft rubber grommet (8) from kit in each of the holes where retaining clips were removed.
3. See Figure 16. Locate and separate front turn signal connector (6-place multilock) under fuel tank. Note wire color and cavity locations.
1Turn signal connector, socket half
2Turn signal connector, pin half
Figure 16. Sportster Front Turn Signal Connector
4. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
5. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
6. Insert combined Y-harness assembly between the two separated front turn signal connectors on vehicle.
7. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assembly (6) installed on bike.
8. Route wire harness cables underneath fuel tank and along appropriate sides of handlebars to holes containing rubber grommets previously installed.
9. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
10. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
Install Y-Harness and Route Cable Through Handlebar - V-Rod Models
VRSCR and VRSCDX Models
1. See Figure 6. Drill a 1/4 in. (6.4 mm) hole in the center of the recessed area of each side of the handlebar.
NOTE
It may be easier to use multiple smaller diameter bits until the 1/4 in. (6.4 mm) diameter is reached.
2. Remove burs from drilled hole.
Figure 17. V-Rod Front Turn Signal Connector (2004-Later)
3. VRSCR Models: See Figure 17. Remove left side cover following the instructions in the Service Manual.
4. Locate and separate front turn signal connector (6-place multilock). Note wire color and cavity locations.
5. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
6. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
7. Insert combined Y-harness assembly between the two separated front turn signal connectors on vehicle.
8. See Figure 4. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assembly (6) installed on bike.
9. Route wire harness cables along appropriate sides of handlebars to holes previously drilled.
10. See Figure 23. Place one hard grommet (21) from kit over the end of each wire harness and slide over cable.
11. See Figure 5. Insert ends of wire harness cables into respective previously drilled holes, and feed cables through handlebars until they come out the ends of handlebars approximately 4 in. (101.6 mm).
12. See Figure 6. Press nylon grommet (3) into handlebar (2) and orient grommet flange along length of recess in handlebar.
13. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
2003-Earlier VRSC Models
1. See Figure 2. Remove turn signal wire retaining clip (1) near the end of each side of the handlebars (2).
2. See Figure 23. Install one soft rubber grommet (8) ( Figure 2 , Item 3) from kit in each of the holes where retaining clips were removed.
3. See Figure 18. Remove instrument cluster following the instructions in the Service Manual.
4. See Figure 3 and Table 1. Locate and separate front turn signal connector inside nacelle. Note wire color and cavity locations.
5. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
1Right handlebar control connectors
2Left handlebar control connectors
Figure 18. V-Rod Handlebar Control Connectors (2003-Earlier)
6. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
7. Insert combined Y-harness assembly between the two separated front turn signal connectors on vehicle.
8. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assembly (6) installed on bike.
9. Route wire harness cables along appropriate sides of handlebars to holes containing rubber grommets previously installed.
10. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
11. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
2004-Later VRSC Models
  1. See Figure 2. Remove turn signal wire retaining clip (1) near the end of each side of the handlebars (2).
  2. See Figure 23. Install one soft rubber grommet (8) ( Figure 2 , Item 3) from kit in each of the holes where retaining clips were removed.
  3. Remove left side cover following the instructions in the Service Manual.
  4. See Figure 3 and Table 1. Locate and separate front turn signal connector inside nacelle. Note wire color and cavity locations.
  5. See Figure 23 and Table 2. Locate 6-place multilock connectors (10, 11) and two Y-harness assemblies (3) from kit. Align both Y-harness assemblies together, matching pin terminated wire ends and socket terminated wire ends.
  6. See Figure 4. Install connectors on ends of combined Y-harness assemblies. Note wire color and cavity locations. Refer to MULTILOCK ELECTRICAL CONNECTORS in Service Manual.
  7. Insert combined Y-harness assembly between the two separated front turn signal connectors on vehicle.
  8. Connect 3-place connectors (5) of wire harnesses (7) ( Figure 23 , Item 19) to 3-place connectors of Y-harness assembly (6) installed on bike.
  9. Route wire harness cables along appropriate sides of handlebars to holes containing rubber grommets previously installed.
  10. See Figure 5. Moisten end of each wire harness cable and slide it through grommet until the end of the cable comes out the end of the handlebar approximately 4 in. (101.6 mm).
  11. Proceed with "Install Circuit Board on End of Handlebar" in this Instruction Sheet.
Install Circuit Board on End of Handlebar
1. See Figure 19. At the unterminated end of harness cable (poking out from end of handlebar), carefully remove 1-1/4 in. (31.8 mm) of sleeving.
NOTE
Use care not to cut the insulation on the three wires inside the harness cable.
2. Strip 1/2 in. (12.7 mm) of insulation from each of the three wires.
3. Fold over the stripped wire to 1/4 in. (6.4 mm) in length, then insert into the connector (butt splice) and crimp with a 22 gauge wire crimper.
Figure 19. Strip, Fold, and Crimp Black Cable Wires
4. See Figure 20. Strip 1/2 in. (12.7 mm) from each wire of the circuit board (1) and fold to 1/4 in. (6.4 mm).
5. Place two pieces of shrink tube 72250 (2) onto the wire harness cable (3) prior to crimping the second half of the connectors (butt splices).
6. Cut the three pieces of shrink tube 72411-97 (4) in half to make six 1 in. pieces (5). Place one piece onto each connector (butt splice), then complete the crimp (6).
7. Heat shrink the 72411-97 tubes over the butt splices.
8. Slide and then shrink one piece of shrink tube 72250-94 on each end of the splice to protect the wires.
1Circuit board
2Shrink tube (2)
3Wire harness cable
4Shrink tube, uncut (3)
5Shrink tube, cut (6)
6Wires crimped
Figure 20. Connect Circuit Board and Wire Harness Cable
9. See Figure 6 and Figure 21. Pull wire harness cable gently back through handlebar to bring circuit board into the opening at the end of the handlebar. The flange of the circuit board holder should be pressed flush with the end of the handlebar.
1Handlebar
2Circuit board
Figure 21. Pull Circuit Board Back into Handlebar
Install Lens Inside Handlebar End Cap
  1. See Figure 22. Assemble outer lens (1), inner lens (2), and retainer (3) inside end cap (4).
  2. Using a snap ring pliers, install snap ring (5) into groove inside end cap.
Install Handlebar Grips and End Caps
  1. See Figure 22. Slide handlebar grips (6) over ends of handlebars as far as they will go.
  2. Snap assembled end caps onto ends of handlebar grips.
1Outer lens, smoked
2Inner lens, clear (skull shown)
3Retainer
4End cap, chrome
5Snap ring
6Handlebar grip
Figure 22. Handlebar End Cap (Right Side)
Final Assembly, Touring Models
  1. FLHR/C/S Models: Install headlamp assembly. Refer to HEADLAMP (FLHR/C/S) in Service Manual. Other Touring Models: Install outer fairing. Refer to UPPER FAIRING/WINDSHIELD in Service Manual.
  2. See Figure 1. Install clutch and brake lever brackets and switch control housings previously removed.
  3. Use cable ties from kit to secure Y-harness assemblies inside headlamp nacelle and wire harness cables to handlebars.
  4. Rotate handlebars both right and left to full stop and check to make sure there is adequate clearance.
  5. Check throttle function for movement and verify it snaps back when grip is rotated.
  6. Install maxi-fuse, left side cover, and left side saddlebag. Refer to MAXI-FUSE and SADDLEBAG in Service Manual.
Final Assembly, Softail Models
  1. See Figure 1. Install clutch and brake lever brackets and switch control housings previously removed.
  2. Use cable ties from kit to secure Y-harness assemblies under fuel tank and wire harness cables to handlebars.
  3. Install fuel tank. Refer to FUEL TANK: CARBURETED or FUEL TANK: EFI in Service Manual.
  4. Rotate handlebars both right and left to full stop and check to make sure there is adequate clearance.
  5. Check throttle function for movement and verify it snaps back when grip is rotated.
  6. Connect battery cables, positive (+) cable first.
  7. Install seat following the instructions in the Service Manual.
Final Assembly, Dyna Models
  1. See Figure 1. Install clutch and brake lever brackets and switch control housings previously removed.
  2. Use cable ties from kit to secure wire harness cables to handlebars.
  3. Secure Y-harness assemblies and wire harness cable inside top frame tube as follows: 2005-Earlier: See Figure 11 and Figure 12. Push Y-harness assemblies and connectors into hole at right side of top frame tube. Pull harness from top frame tube at service loop and secure with clips. Install plug on right side of top frame tube. 2006-Later: See Figure 13. Push Y-harness assemblies and connectors into opening under top frame tube, then install cover on tube.
  4. Install fuel tank. Refer to FUEL TANK in Service Manual.
  5. Install seat following the instructions in the Service Manual.
  6. Rotate handlebars both right and left to full stop and check to make sure there is adequate clearance.
  7. Check throttle function for movement and verify it snaps back when grip is rotated.
  8. Connect battery cables, positive (+) cable first.
Final Assembly, Sportster Models
  1. See Figure 1. Install clutch and brake lever brackets and switch control housings previously removed.
  2. Use cable ties from kit to secure Y-harness assemblies under fuel tank and wire harness cables to handlebars.
  3. Install fuel tank. Refer to FUEL TANK in Service Manual.
  4. Install seat following the instructions in the Service Manual.
  5. Rotate handlebars both right and left to full stop and check to make sure there is adequate clearance.
  6. Check throttle function for movement and verify it snaps back when grip is rotated.
  7. Install maxi-fuse and left side cover. Refer to MAXI-FUSE in Service Manual.
Final Assembly, V-Rod Models
  1. See Figure 1. Install clutch and brake lever brackets and switch control housings previously removed.
  2. 2003-Earlier: Use cable ties to secure Y-harness assemblies and connectors to handlebars and secure wires inside instrument cluster. Install instrument cluster following the instructions in the Service Manual. 2004-Later: Use cable ties to secure Y-harness assemblies and connectors to handlebars and secure wires inside left side cover and instrument cluster. Install left side cover following the instructions in the Service Manual.
  3. Rotate handlebars both right and left to full stop and check to make sure there is adequate clearance.
  4. Check throttle function for movement and verify it snaps back when grip is rotated.
  5. Install maxi-fuse and right side cover. Refer to MAXI-FUSE in Service Manual.
SERVICE PARTS
Figure 23. Service Parts: Lighted Handlebar End Caps
Table 4. Service Parts: Lighted Handlebar End Caps
Item
Description (Quantity)
Part Number
1
Snap ring (2)
56882-06
2
Circuit board (2)
56881-06
3
Y-harness assembly (2) (includes fuse holders and fuses)
56873-06
Fuse, 1 amp glass (4) (not shown)
56880-06
4
Retainer (2)
56879-06
5
Inner lens, clear (Bar and Shield) (2)
56878-06
Inner lens, clear (Skull) (2)
56877-06
Inner lens, clear (Custom) (2)
56875-06
6
Outer lens, smoked (2)
56876-06
7
End cap, chrome (2)
56874-06
8
Grommet, rubber (2)
11437
9
Cable strap (10)
10006
10
Socket housing, 6-place (1)
73156-96BK
11
Pin housing, 6-place (1)
73106-96BK
12
Socket housing, 4-place (2)
73154-96BK
13
Pin housing, 4-place (2)
73104-96BK
14
Socket housing, 3-place (2)
73153-96BK
15
Pin housing, 3-place (2)
73103-96BK
16
Connector (butt splice) (6)
70581-73
17
Shrink tube (3)
72411-97
18
Shrink tube (4)
72250-94
19
Wire harness assembly (2)
56912-06
20
Jumper wire assembly (2)
56913-06
21
Grommet, nylon (2)
11610
Electrical Connections:
A
Y-harness to Y-harness
B
Y-harness to front turn signal connectors
C
Y-harness to wire harness
D
Wire harness cable to circuit board
Item mentioned in text, but not part of kit:
E
Handlebar grip, right side shown