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1125CR CLUBMAN HANDLEBAR KIT
J049062009-06-10
GENERAL
Kit Number
N2002B.1AT, N2002C.1AT
Models
For model fitment information, see the Buell Accessories and Parts Countertop Reference Guide (CRG) or the Accessories section of www.buell.com (English only).
Tools and Supplies Required
Fresh, uncontaminated DOT 4 hydraulic brake fluid from a sealed container will be needed.
WARNING
The rider's safety depends 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 Buell dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00334a)
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Buell dealer.
Kit Contents
See Figure 4 and Table 1.
REMOVAL
NOTE
Refer to the service manual and follow instructions to perform the following tasks.
Note the routing of the front brake line, clutch line, throttle cables and mirror wires before removal.
1. Remove the windscreen.
2. Disconnect the clutch switch [95].
3. Disconnect the front brake switch [170].
4. Remove the mirrors.
NOTE
Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping the affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills).
Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to the finish caused by spillage or splash of DOT 4 brake fluid.
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
5. Drain the front brake fluid and remove the brake line.
6. Remove the front brake master cylinder.
7. Remove the throttle cables.
8. Remove the right side switch housing and hand grip (throttle tube). Save the hand grip for later installation.
9. Drain the clutch fluid and remove the clutch line.
10. Remove the clutch master cylinder.
11. Remove the left side switch housing.
12. Remove the handlebar with left hand grip.
INSTALLATION
NOTE
Refer to the service manual and follow instructions to perform the following tasks.
1. Install the new handlebar with the clamp and fasteners removed earlier.
2. Install the left switch housing. Verify that the alignment pin on the switch housing is seated in the locating hole in the handlebar.
1Lever/clamp split alignment mark
2Lever/clamp outboard alignment mark
3Left switch housing outboard alignment mark
Figure 1. Lever Clamp and Switch Housing Alignment Marks
3. See Figure 1. Install the clutch master cylinder, aligning with the marks on the handlebar.
4. Install the clutch line.
NOTICE
DOT 4 hydraulic brake fluid is used in the hydraulic clutch. Do not use other types of fluids as they are not compatible and could cause equipment damage. (00353b)
5. Fill the clutch master cylinder with DOT 4 hydraulic brake fluid. Bleed the system.
6. Install the new left hand grip.
7. Install the right hand grip (throttle tube) and throttle cables.
8. Install the right switch housing. Verify that the alignment pin on the switch housing is seated in the locating hole in the handlebar.
9. See Figure 1. Install the front brake master cylinder, aligning with the marks on the handlebar.
10. See Figure 2. Install the front brake line.
Figure 2. Brake Line Routing
WARNING
Use only DOT 4 hydraulic brake fluid in the brake master cylinder. Use of other types of fluid can cause brake system damage and adversely affect braking, which could result in death or serious injury. (00597c)
11. Fill the front brake master cylinder with DOT 4 hydraulic brake fluid. Bleed the system.
12. Install the mirrors.
13. Install the end caps.
14. Adjust the throttle cables.
15. See Figure 3. Pull the front brake and clutch switch wires through the vertical slots on each side of the headlight housing. Connect the switches.
16. Test the brakes, throttle, clutch and turn signals for proper operation.
17. Install the windscreen.
1Vertical slot (2)
2Brake switch wire
3Clutch switch wire
Figure 3. Route Brake and Clutch Switch Wires
SERVICE PARTS
Figure 4. Service Parts, Handlebar Kit
Table 1. Service Parts
Item
Description (Quantity)
Part Number
1
Brake line assembly, front
H2531.1AM
2
End cap (2)
N0010.02A8
3
Hand grip, left (not shown)
N0050.K
4
Clutch hose assembly
N0103.1AT
5
Throttle cable, open (for Kit N2002B.1AT)
Throttle cable, open (for Kit N2002C.1AT)
N0307.1AM
N0307A.1AM
6
Throttle cable, close (for Kit N2002B.1AT)
Throttle cable, close (for Kit N2002C.1AT)
N0308.1AM
N0308A.1AM
7
Handlebar
N0037.1ATCZT
8
Cable tie (3) (not shown)
Y0303.2B