16-INCH APE HANDLEBAR

J051552010-02-03

GENERAL

Kit Numbers

57483-11, 57484-11

Models

For model fitment information, see the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

Additional Parts or Accessories Required

Separate purchase of additional parts or accessories are required for proper installation of this handlebar kit.

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)

For XL Models the following kits are required for proper installation:

Clutch Cable Kit: Diamondback (38851-09) or Diamond-Black (38818-10)
Throttle/Idle Cable Kit: Diamondback (39005-11) or Diamond-Black (39008-11)
Brake Line Kit: Diamondback (38180-11) or Diamond-Black (38182-11)
Extended Wire Handlebar Switch Kit (70318-10)
6-Inch Turn Signal Extention Wire Extention (72137-03)

For FXDB Models the following kits are required for proper installation:

Clutch Cable Kit: Diamondback (38857-09) or Diamond-Black (38975-10)
Throttle/Idle Cable Kit: Diamondback (56100011) or Diamond-Black (56100013)
Upper Brake Line Kit: Diamondback (42752-07) or Diamond-Black (41800048)
Lower Brake Line Kit: Diamondback (42110-07) or Diamond-Black (38116-10)

The two brake line gaskets found at each banjo fitting must be replaced. Refer to the parts catalog for this year/model motorcycle or see a Harley-Davidson^® dealer for the correct part numbers.

Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately.

Refer to the parts catalog for replacement original equipment (OE) hand grips.
Refer to the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) to see the selection of Genuine Motor Accessory hand grips that are available.

Tools and Supplies Required

Loctite^® 271 Threadlocker and Sealant - Red (H-D Part No. 99671-97) is required for the proper installation of this kit.

Fresh, uncontaminated hydraulic brake fluid. Refer to the owner's manual or service manual for this year/model motorcycle to determine the correct brake fluid for this vehicle.

These items are available from a Harley-Davidson dealer.

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 refers to service manual information. A service manual for this year/model motorcycle is required for this installation and is available from a Harley-Davidson dealer.

Kit Contents

This kit contains one handlebar.

REMOVAL

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.	Refer to the service manual and follow the instructions given to remove the seat and disconnect the battery cables, negative (-) cable first. Retain all seat mounting hardware.
	WARNING When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)
2.	See the service manual and loosen or remove the fuel tank.

If able to access all harness and throttle cable connections, the fuel tank may be moved up and rearward without disconnecting the fuel line or crossover.
If NOT able to access these connections, the fuel tank will have to be completely removed and set aside for later installation.

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)

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)

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 an H-D Service Cover or polyethylene protective sheet to help protect against damage to the finish caused by spillage or splash of DOT 4 brake fluid.

NOTE

Refer to the service manual for specific instructions on the following generalized steps.

Remove or loosen fuel tank.
Disconnect turn signal connectors.
For XL models: Remove front turn signals and wiring.
Drain the brake fluid from the front brake reservoir and brake lines.
Remove throttle/idle cables and right controls.
Remove clutch control and clutch cable.
Remove handlebar.
For FXDB models: Remove front turn signals and wiring.
Remove grips.

INSTALLATION

XL Models

NOTE

The torque value shown below is different from the value given in the service manual.

1.	See the service manual. Install handlebar to risers. Tighten to 21.7 N·m (16 ft-lbs).
2.	See the service manual and install the front brake master cylinder.
3.	See the service manual Install left hand grip. See the

FXDB Models

NOTE

The torque value shown below is different from the value given in the service manual.

1.	See the service manual. Install handlebar to risers. Tighten to 21.7 N·m (16 ft-lbs). NOTE This handlebar kit does not allow for internal wiring of the handlebar. All turnsignal wiring must be routed externally.
2.

FINAL ASSEMBLY

WARNING

When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)

Dyna and Softail Models

Install the fuel tank per instructions in the service manual. Proceed to "SAFETY CHECK".

Road King Models

1.	If loosened or removed, install the fuel tank per instructions in the service manual.
2.	See FLHR Ape Handlebar Riser Configuration . To avoid possible damage to the brake line, verify that the edge protectors (10) remain installed on the inside edges of the headlamp nacelle (11). Replace the edge protectors if missing, cracked or damaged.
3.	See Figure 1. Loosen the two acorn nuts securing the left half of the nacelle (see arrows). Repeat for the right half of the nacelle.	Figure 1. Headlamp Nacelle Fasteners (FLHR Models)
4.	See FLHR Ape Handlebar Riser Configuration . Fasten the new handlebar cover (1) to the fork lock (2) mechanism. For North America: use the two flat head screws (12) removed earlier. Tighten the flat head screws to 1.1–2.3 N·m (10–20 in-lbs). For Australia, Brazil, England, Europe and Japan: use two new special screws (H-D Part No. 2935A, purchased separately). Tighten the screws (12) until the break-away heads snap off.
5.	Press the original fork lock plate (13) into position on the handlebar cover.
6.	Insert the screw (14, removed earlier) through the hole at the front of the handlebar cover and the top of the headlamp nacelle (11). Reach inside the nacelle and install the nut (15) and flat washer (16) onto the screw threads. Tighten the screw to 1.1–2.3 N·m (10–20 in-lbs).
7.	Insert the hook of the trim strip (17) into the slot on the handlebar cover. Insert the weld studs (18) on the trim strip into the holes at the top of the headlamp nacelle, and reach inside the nacelle to install the flange nut (19). Tighten the nut to 1.7–2.3 N·m (15–20 in-lbs).
8.	See the service manual to install the headlight into the nacelle.
9.	Install the windshield, if equipped.

SAFETY CHECK

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 wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops.

NOTE

Verify that the ignition key switch is in the OFF position before attaching the battery cables.

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.	Refer to the service manual and follow the instructions given to attach the battery cables (positive cable first). Apply a light coat of Harley-Davidson electrical contact lubricant (H-D Part No. 99861-02), petroleum jelly or corrosion retardant material to the battery terminals.
	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 key switch to IGNITION, but do not start the motorcycle. Test each handlebar switch for proper operation.
3.	Turn the handlebar to the left and right steering stops, testing the handlebar control functions at each stop.
4.	Apply 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)
5.	Refer to the service manual, and follow instructions to install the seat.

WARNING

Before 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)

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)

SERVICE PARTS

Table 1. Service Parts: Fat Ape and Fat Mini-Ape Handlebar Kits

Kit	Item	Description (Quantity)	Part Number
Kit 55857-10 Fat Ape Handlebar (Satin Black finish)	1	Handlebar, Fat Ape, 0.4 m (16 in) high, Satin Black	Not sold separately
Kit 55857-10 Fat Ape Handlebar (Satin Black finish)	2	One-Piece Fat Handlebar Riser Kit (Black)	56931-10
Kit 55859-10 Fat Mini Ape Handlebar (Satin Black finish)	1	Handlebar, Fat Mini Ape, 0.3 m (12 in) high, Satin Black	Not sold separately
Kit 55859-10 Fat Mini Ape Handlebar (Satin Black finish)	2	One-Piece Fat Handlebar Riser Kit (Black)	56931-10
Kit 56832-04A Fat Mini Ape Handlebar (Chrome finish)	1	Handlebar, Fat Mini Ape, 0.3 m (12 in) high, Chrome	Not sold separately
Kit 56832-04A Fat Mini Ape Handlebar (Chrome finish)	2	One-Piece Fat Handlebar Riser Kit (Chrome)	56929-10
Kit 56942-10 Fat Ape Handlebar (Chrome finish)	1	Handlebar, Fat Ape, 0.4 m (16 in) high, Chrome	Not sold separately
Kit 56942-10 Fat Ape Handlebar (Chrome finish)	2	One-Piece Fat Handlebar Riser Kit (Chrome)	56929-10
Items common to ALL kits	3	Handlebar grommet, large (2)	11386
	4	Handlebar grommet, small (2)	11398
	5	Heat-shrink tube, large	72162-02
	6	Heat-shrink tube, small	72165-02
Items mentioned in text, but not included in kit:
	A	Original equipment (OE) cup washer, upper (install flat side up) (2)
	B	OE bushing (4)
	C	OE spacer (2)
	D	OE cup washer, lower (install flat side down) (2)
	E	OE flat washer (2)
	F	OE split lockwasher (2)
	G	OE ground wire
	H	OE internal-tooth lockwasher
	I	OE riser mounting screw (2)
	J	Large wire opening (2)
	K	Small wire opening (2)

SERVICE PARTS

Figure 2. Service Parts: Fat Ape and Fat Mini-Ape Handlebar Kits

Figure 3. Service Parts:Twist Grip Sensor Kit (32310-08)

Table 2. Service Parts: Twist Grip Sensor Kit (32310-08)

Item	Description (Quantity)	Part Number
Items for Twist Grip Sensor:
7	Sensor, twist grip (TGS)	Not sold separately
8	Pin housing, six-way	72188-07BK
9	Anchor, connector T-stud	73212-07
10	Cable strap	10006
11	Tubing, PVC	Not sold separately
Items used with Heated Hand Grips only:
12	Socket housing, two-way	72112-94BK
13	Secondary lock, two-way socket housing	72152-94
14	Seal pin (plug) (2)	72195-94
15	Pin housing, two-way	72102-94BK
16	Secondary lock, two-way pin housing	72142-94
Items mentioned in text:
L	Heated handgrip wire and socket terminal (2)
M	Twist grip sensor pin terminal (6)