Clip-Ons for XL Models
J064582017-02-27
GENERAL
This Kit Requires Dealer Installation
WARNINGThe rider’s safety depends on the proper installation of this kit. Dealer installation is required. Incorrect or incomplete installation can adversely affect motorcycle operation, which could result in loss of control and death or serious injury. (02504a)
Kit Number
55800646 , 55800647 , 55800668
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Installation Requirements
Separate purchase of additional parts or accessories is 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. For 883N and 1200X must purchase lock nut (2) and washer (2). Table 2
Some models require a turn signal relocation kit. Refer to Table 1.
WARNINGReplace 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)
Table 1. Clip-on Turn Signal Relocation Kit
Model(s) | Part Number |
|---|---|
2014-Later 883N | 68643-09 |
2014-2015 1200X | 67800452 |
2016-Later 1200X | 67800557 |
Motorcycles equipped with a glued left side hand grip 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.
REMOVAL
WARNINGTo prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
| 1. | See the service manual. Remove main fuse. | |
| 2. | See the service manual. Remove the original equipment (OE) handlebar, hand controls, clutch and throttle/idle cables and front brake lines. 1200CX Models: Reuse the stock cables and brake lines. | |
| 3. | All Models Except 1200CX: See the service manual. Remove speedometer and speedometer housing. |
INSTALLATION
| 1. | See Figure 1. Loosen fork stem pinch screw (1). | |||||||||
| 2. | Loosen upper bracket pinch screws (2). | |||||||||
| 3. | Remove fork stem bolt (3). | |||||||||
| 4. | Loosen upper bracket screws (2). | |||||||||
| 5. | Remove upper fork bracket (4). | 
Figure 1. Upper fork bracket | ||||||||
| 6. | See Figure 2. Slide the clip-on assembly (1) over the fork tube. The Harley-Davidson logo (2) should be right side up facing out. | |||||||||
| 7. | The center index mark (3) should align with the indicator on the clamp. | |||||||||
| 8. | Do not tighten at this time. | |||||||||
| 9. | Repeat sliding the other clip-on on the other fork tube. | |||||||||
| 10. | See Figure 1. Set the upper fork bracket in place. | |||||||||
| 11. | Install fork stem bolt (3). Finger tighten at this time. | |||||||||
| 12. | Install bracket pinch screws (2). Finger tighten at this time. | |||||||||
| 13. | See Figure 3. Slide the clip-on assemblies up the fork tubes until they touch the bottom of the upper fork bracket. |
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)
- Make sure throttle/idle control cables do not pull tight when handlebars are turned fully to left or right fork stops.
| 14. | Position the clip-on handle bars so they are in the desired position. | |||||||||||||||
| 15. | Verify that wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops. | |||||||||||||||
| 16. | Verify that there is adequate clearance between the handlebar and the fuel tank when the handlebars are turned to the left and right stops. | |||||||||||||||
| 17. | Tighten screw (3) to: Torque: 33.9–40.6 N·m (25–30 ft-lbs) Head screw | |||||||||||||||
| 18. | Tighten screws (4) to: Torque: 12.2–13.5 N·m (108–120 in-lbs) Head screw NOTE When routing and securing control wires, make sure that wires do not pull tight at either steer stop. | 
Figure 2. Clip-on handlebar, (right side shown) 
Figure 3. Clip-on handlebar installation | ||||||||||||||
| 19. | See the service manual. Install the left and right hand controls. | |||||||||||||||
| 20. | Install hand grips. Follow the instructions included in that kit. | |||||||||||||||
| 21. | Install hand mirrors. Follow the instructions included in that kit. | |||||||||||||||
| 22. | See the service manual. Follow the Fall-Away procedure. | |||||||||||||||
| 23. | Some models: Install front turn signal relocation kit. See Table 1. See the instructions in that kit for instillation. | |||||||||||||||
| 24. | All Models Except 1200X: Install the speedometer in the new speedometer housing and install on motorcycle following instructions in that kit. |
WARNINGThe rider's safety depends upon the correct installation of this kit. Dealer installation is required for vehicles equipped with ABS brakes. Proper installation of this kit requires the use of special tools available only through a Harley-Davidson Dealer. An improperly serviced brake system can adversely affect brake performance, which could result in death or serious injury. (00578b)
WARNINGContact 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
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)
WARNINGReplace 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)
| 1. | ABS Models: The brake line at the master cylinder needs to be removed and re-installed so the curved fitting faces outboard. a. See Figure 4 and Figure 5. Note that the brake line fitting (3) faces in-board. Remove banjo bolt (1). Retain for reuse. Remove sealing washers (2). Discard sealing washers. Loosen the brake line at the manifold below the lower fork bracket. b. Rotate the brake line so that the fitting faces out-board. Install new sealing washers (part number 41756-08). Secure brake line with banjo bolt removed earlier. Tighten Torque: 19–24 N·m (14–18 ft-lbs) Head screw. c. See service manual for brake bleeding procedures. | 
Figure 4. Brake Line Fitting, Banjo Bolt, and Seal 
Figure 5. Brake Line Fitting, Banjo Bolt, and Seal | ||||||||||||
| 2. | 1200 CX Models: Reuse the stock (OE) cables and lines. Use the same routing as the stock (OE) cables. NOTE When installing the clip-on handlebars, make sure that there is adequate clearance between the handlebar and the fuel tank. | |||||||||||||
| 3. | Install the new clutch cables, throttle/idle cables and front brake lines. Follow the instruction sheets included in those kits. | |||||||||||||
| 4. | See Figure 6. The clip-on handlebars can be rotated slightly if desired. | |||||||||||||
| 5. | Note the alignment of the clip-on index mark(s) (2) to the indicator on the clamp (3). | |||||||||||||
| 6. | Loosen screws (4). | |||||||||||||
| 7. | Rotate clip-on handlebars and hand controls. | |||||||||||||
| 8. | Tighten screws (4) to: Torque: 12.2–13.5 N·m (108–120 in-lbs) Head screw | 
Figure 6. Clip-on handlebar, installed with hand controls | ||||||||||||
| 9. | 1200X and 883N Models: Discard OE mirror mounting nuts. | |||||||||||||
| 10. | See Table 2. Use separately purchased lock nut 7725 (2) and lock washer 7155 (3) to mount mirror to bike. | |||||||||||||
| 11. | See service manual for torque. |
Table 2. Purchased Parts
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
1200X (required separate purchase) | 2 | Lock nut (2) | 7725 |
3 | Lock washer (2) | 7155 |
SAFETY CHECK
| 1. | Verify that the ignition switch is turned to OFF. | |
| 2. | Install the main fuse. See the service manual. | |
| 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) | ||
| 3. | Turn the ignition switch to IGNITION, but do not start the engine. Test all switches and lights for proper operation. |
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)
SERVICE PARTS
Figure 7. Service Parts: Clip-on Handlebars for XL Models
Table 3. Service Parts
Kit | Item | Description (Quantity) | Part Number |
|---|---|---|---|
55800646 | 1 | Clip-on handlebar assembly, 55MM, left side | 55800654 |
2 | Clip-on handlebar assembly, 55MM, right side | 55800655 | |
3 | Screw, T30 (4) | 94314-91T | |
4 | Screw, T50 (2) | 94354-91T | |
5 | Clip-on handlebar (2) | Not Sold Separately | |
6 | Clip-on clamp, 55MM, left side | Not Sold Separately | |
7 | Clip-on clamp, 55MM, right side | Not Sold Separately | |
55800647 | 1 | Clip-on handlebar assembly, 39MM, left side | 55800657 |
2 | Clip-on handlebar assembly, 39MM, right side | 55800656 | |
3 | Screw, T30 (4) | 94314-91T | |
4 | Screw, T50 (2) | 94354-91T | |
5 | Clip-on handlebar (2) | Not Sold Separately | |
6 | Clip-on clamp, 39MM, left side | Not Sold Separately | |
7 | Clip-on clamp, 39MM, right side | Not Sold Separately | |
55800668 | 1 | Clip-on handlebar assembly, 49MM, left side | 55800666 |
2 | Clip-on handlebar assembly, 49MM, right side | 55800664 | |
3 | Screw, T30 (4) | 94314-91T | |
4 | Screw, T50 (2) | 94354-91T | |
5 | Clip-on handlebar (2) | Not Sold Separately | |
6 | Clip-on clamp, 49MM, left side | Not Sold Separately | |
7 | Clip-on clamp, 49MM, right side | Not Sold Separately |
| 2 | Lock washer (2) |
| 3 | Lock nut (2) |
| A | Mirror assembly, right |
| B | Mirror assembly, left |
Figure 8. Upper Fork Mirror Assembly