TALL HANDLEBAR KIT
J042742008-10-23
GENERAL
Kit Number
56964-07
Models
Ask a Harley-Davidson dealer or refer to the latest Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts catalog to determine if this handlebar can be installed on your motorcycle.
Additional Parts Required
Separate purchase of additional parts or accessories may be required for proper installation of this handlebar kit on your model motorcycle. Refer to the latest Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts catalog for a list of required parts or accessories for your model.
Motorcycles equipped with a glued left side hand grip will also require a new grip, sold separately.
FLHX Models require separate purchase of handlebar-mounted mirrors. If fairing-mounted mirrors are to be removed, separate purchase of two small (part number 755) and two large (part number 732) hole plugs is recommended.
Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips and handlebar-mounted mirrors (for FLHX models) 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.
Tools and Supplies Required
Fresh, uncontaminated brake fluid will be needed. Refer to the owner's manual or the service manual to determine the correct brake fluid required.
A long shank ball-end socket (Snap-on® FABL6E or equivalent) will also be needed to remove and install the radio or storage box.
REMOVAL
Models with Main Fuse
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
- Refer to the service manual and follow the instructions given to remove the main fuse.
Models without Main Fuse
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
- Refer to the service manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Save all seat mounting hardware.
- Remove the outer fairing. See the service manual. Remove the fairing cap. See the service manual.
- Bleed the brake fluid from the front brakes per the instructions in the service manual.
Handlebar Removal
NOTE
Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result.
| 1. | 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. | |
| 2. | Models with Radio: Remove the radio. See the service manual. Models without Radio: Remove the storage box. a. The four socket head screws fastening the 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 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) | ||
| 3. | Disconnect the front brake lines from the vehicle. See the service manual. | |
| 4. | Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. | |
| 5. | Remove the old front brake lines from the motorcycle. | |
| 6. | Remove the front brake master cylinder and clutch lever assemblies from the handlebar. | |
| 7. | Refer to the service manual and follow the instructions to disconnect the clutch cable from the clutch lever. Disconnect the clutch cable from the side cover and remove the cable from the vehicle. NOTE Molex connectors are used for the handlebar control wiring on 2007 and later models. 2006 and earlier vehicles use Deutsch connectors. Refer to the service manual for disconnection and connection procedures. Note the wire routing before disconnecting the handlebar control wiring. | |
| 8. | Disconnect the handlebar control wiring from the gray and black 6-way main harness connectors inside the fairing. Disconnect the electronic cruise control wiring from the two 4-way connectors if equipped. | |
| 9. | Refer to the service manual and remove the right side switch housing assembly and harness to access the throttle cables. | |
| 10. | Refer to the service manual and disconnect the throttle cables from the existing right grip/throttle sleeve assembly, and the carburetor or induction module. Remove the throttle cables from the vehicle. | |
| 11. | Refer to the service manual and remove the left side switch housing assembly and wire harness. | |
| 12. | See Figure 1. Remove and retain the screws (1) and flat washers (2) that secure the handlebar upper clamps (3) to the risers (5). Remove and retain the clamps. Remove the handlebar (4) from the motorcycle. | |
| 13. | 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. NOTE DO NOT remove the wires from the Molex or Deutsch handlebar switch connector pin housings inside the fairing. | |
| 14. | Note the wire colors and positions in each cavity of the socket housings leading from the switches. Refer to the wiring diagram and the instructions in the service manual. Remove the wires from the socket housings. |
| 1 | Clamp screw (4) |
| 2 | Flat washer (4) |
| 3 | Upper clamp (2) |
| 4 | Handlebar |
| 5 | Handlebar riser (2) |
Figure 1. Handlebar Clamps and Risers
INSTALLATION
| 1. | See Figure 2. Cut the rubber sleeve (2) into two equal lengths. Slide a section of the sleeve onto each of the switch wire bundles, positioning the sleeve close to the switch end. | |
| 2. | Center the new handlebar on the risers. Make sure that the handlebar is centered by verifying that the knurled areas on the outboard side of each riser are equal. | |
| 3. | Position the original equipment handlebar upper clamps and install with the clamp screws and flat washers saved earlier. Tighten the screws finger-tight. | |
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) | ||
| 4. | Slowly turn the front wheel to the full-right fork stop and then the full-left fork stop to be sure the handlebar does not contact the fuel tank. If contact occurs and the handlebars are properly centered, raise the handlebar angle as necessary until proper clearance is obtained. | |
| 5. | Tighten the upper handlebar clamp screws as follows: a. Tighten the front screws until the upper handlebar clamps make contact with the handlebar riser. b. Tighten the rear screws to 16.3–21.7 N·m (12–16 ft-lbs). c. Tighten the front screws to 16.3–21.7 N·m (12–16 ft-lbs). NOTE There will be a slight gap between the upper clamps and the risers toward the rear of the handlebars after tightening. | |
| 6. | Refer to the service manual and follow the instructions given to install the new throttle control cables and a new (purchased separately) or original right grip/throttle sleeve assembly. | |
| 7. | Refer to the service manual to route the new throttle and idle cables to the carburetor or induction module. | |
| 8. | Loosely fasten the brake lever clamp to the new handlebar. | |
| 9. | Slide the rubber sleeve on the right side handlebar switch wires over the right side end of the new handlebar. Position the rubber sleeve over the switch wires inside the switch housing. Push the switch and rubber sleeve into the slot on the new handlebar. Loosely fasten the handlebar switch housing to the handlebar. | |
| 10. | Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort and posture. The brake master cylinder must be horizontally level. NOTE Tighten the top brake lever clamp screw before tightening the bottom screw. | |
| 11. | Tighten first the top, then the bottom brake lever clamp screws to 8–9 N·m (71–80 in-lbs). NOTE Tighten the lower switch housing screw before tightening the upper screw. This will leave any gap in the switch housing at the front for best appearance. | |
| 12. | Tighten first the lower, then the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs). | |
| 13. | 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. | |
| 14. | Install a new (purchased separately) or original hand grip on the left end of the new handlebar according to the hand grip instruction sheet or the instructions in the service manual. | |
| 15. | Slide the rubber sleeve on the left side handlebar switch wires over the left side end of the handlebar. Position the rubber sleeve over the switch wires inside the switch housing. Push the switch and rubber sleeve into the slot on the new handlebar. Loosely fasten the handlebar switch housing to the handlebar. Refer to the service manual. | |
| 16. | Adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort and posture. | |
| 17. | Tighten first the top, then the bottom clutch lever clamp screws to 8–9 N·m (71–80 in-lbs). | |
| 18. | Tighten first the lower, then the upper switch housing screws to 4–5.1 N·m (35–45 in-lbs). NOTE Molex connectors are used for the handlebar control wiring on 2007 and later models. 2006 and earlier vehicles use Deutsch connectors. Refer to the service manual for connection procedures. | |
| 19. | Refer to the notes made during the removal steps, and the wiring diagram and instructions in 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. | |
| 20. | Insert each socket terminal from the right side switch wire bundle into the correct cavity of the black socket housing removed earlier. | |
| 21. | Insert each socket terminal from the electronic cruise-control wire bundle into the correct cavity of the two 4-way connectors removed earlier, if equipped. | |
| 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) | ||
| 22. | Carefully inspect the new brake line for damage or defects, and replace if damaged. Install the brake line per the service manual instructions or the instructions included with the Brake Line Kit. | |
| 23. | Bleed the brakes. See the service manual. | |
| 24. | Install the new clutch cable per the instructions in the service manual. | |
| 25. | FLHX Models: Install handlebar-mounted mirrors per the instructions in the service manual. |
Safety Check
WARNINGBe 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 wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops.
| 1. | Verify that the ignition/light key switch is turned to the OFF position. Apply a light coat of petroleum jelly or corrosion-retardant material to the negative battery terminal. Refer to the service manual and follow the instructions given to connect the negative (-) battery cable. | |
| 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 to IGNITION and test each handlebar switch for proper operation. | |
| 3. | Actuate the front brake hand lever to test operation of the brake lamp. | |
| WARNING After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b) WARNINGBefore 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) WARNINGAfter 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) | ||
| 4. | Refer to the service manual and follow instructions to install the seat. |
SERVICE PARTS
Figure 2. Service Parts
Table 1. Service Parts Table
Item | Description (Quantity) | Part Number |
|---|---|---|
1 | Handlebar | Not sold separately |
2 | Sleeve, rubber | Not sold separately |
Items mentioned in text, but not included in kit: | ||
A | Original equipment handlebar riser (2) | |
B | Original equipment handlebar upper clamp (2) | |
C | Original equipment handlebar clamp screw (4) | |
D | Original equipment flat washer (4) | |