1 | Screw (2) |
2 | Handlebar clamp |
3 | Clutch hand lever assembly |
4 | Upper switch housing |
5 | Lower switch housing |
6 | Left handlebar grip |
7 | Larger diameter of flange |
8 | Grooves |
1. | Refer to the service manual for specific information on the following generalized steps. | |||||||||||||||
2. | With "glueless" grip: Remove the grip from the handlebar. With glued grip: Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. |
Figure 2. Left Handlebar Switch Housing (2014-Later Touring) |
1 | 5/32-inch (4 mm) thick insert |
2 | Brake lever |
3 | Brake lever bracket |
1 | Handlebar |
2 | Throttle twist grip sensor |
3 | Seal cap |
1. | See TWIST GRIP SENSOR: REMOVAL in the service manual. Follow the instructions for the specific model vehicle to: a. Access the six-way twist grip sensor jumper harness connector [204] inside the vehicle. Unplug the connector halves. b. Gently pull twist grip sensor out of handlebar only as far as necessary to access black heat shrink tubing or heated grip connector. | |
2. | See Figure 8. Get the left side heated grip (1), long wire harness (15) and short wire harness extension (8) from the kit. Determine if the extension is required for this installation: Does the connector extend past the opposite end of the handlebar? If YES: The extension is not needed. It can be discarded. Disconnect the wire harness from the left side grip. If NO: Disconnect the wire harness from the left side grip. Connect the extension to the connector on the wire harness. Set the left side grip, and the wire harness or harness assembly aside. a. Temporarily connect the wire harness to the connector on the end of the left heated hand grip. b. Hold the grip and attached wire harness in position along outside of handlebar as if the assembly were installed on the handlebar. c. The connector at the end of the wire harness must extend past the right end of the handlebar. NOTE DO NOT cut any wires leading to the green connector on the twist grip sensor. Cut off the black heat shrink tubing ONLY. d. Locate the pass-thru connector on the twist grip sensor. This is a 2-way pin side connector see service manual for location. | |
3. | Locate the black harness coming from the center of the twist grip sensor. | |
4. | Get the wire harness set aside in Step 2. | |
5. | Connect the socket housing on the sensor wires to the black pin housing at the end of the wire harness. NOTE Air pressure or an electrical fish tape can be used to thread the wire harness completely through the handlebar. | |
6. | Thread the connector and twist grip sensor wire harnesses into the right side of the handlebar. a. While feeding the wiring into the handlebar, gently pull the connector at the end of the twist grip sensor jumper harness to draw the twist grip sensor into the handlebar. b. Thread the left side heated grip wire harness all the way through and out the left side of the handlebar. c. Fit the index tabs on the twist grip sensor into the slots in the handlebar. One index tab and one slot are smaller than the others to prevent improper assembly. NOTE
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7. | Fasten the white socket housing to the new left side heated hand grip (1). |
1. | See Figure 1. Position the left side heated grip (6) so the larger diameter portion of the flange (7) is at the bottom. Push the grip fully onto the handlebar. a. Position the lower switch housing beneath the grip. The grooves (8) on the outboard side of the switch housing must fit over the flange on the end of the grip. b. Position the upper switch housing over the handlebar and lower switch housing. c. Start the upper and lower switch housing screws, but do not tighten. Verify that the wire harness conduit runs in the depression at the bottom of the handlebar. d. Position the clutch hand-lever assembly inboard of the switch housing assembly. Engage the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. e. Align the hole in the handlebar clamp with the hole in the clutch lever bracket. Start the lower screw with flat washer. Adjust the switch housing and clutch hand control position for rider comfort. f. Tighten first the upper, then the lower handlebar clamp screws. Torque: 6.8–9 N·m (60–80 in-lbs) g. Tighten first the lower, then the upper switch housing screws. Torque: 4–5.4 N·m (35–48 in-lbs) |
1. | See Figure 5. Locate the B+ (battery positive) connector (1) on the main electrical harness under the seat (a red wire with an unused gray connector). Remove the cover (2) from the connector. | |||||||
2. | See Figure 8. Plug the adapter harness (11) from the kit into the B+ connector. | |||||||
3. | Cut the heated hand grip harness red wire to within easy reach of the end of the adapter harness red wire. Use a sealed splice connector (4) from the kit to splice the two wires per the service manual. |
Figure 5. B+ Connector | ||||||
4. | Get the orange/white fuse block adapter wire (10) from the kit. Note the terminal on each end (see Figure 6. Only the terminal WITHOUT the spring tabs fits into the fuse cavity. Carefully cut the terminal WITH spring tabs from the wire and discard it. |
Figure 6. Fuse Block Adapter Wire | ||||||
5. | Locate the fuse cavity indicated as "P&A IGN" "2A MAX". There is a bus bar feeding one side of this circuit, but no mating wire or fuse is present. Remove the three existing fuses in this row, noting their location. | |||||||
6. | Gently remove the orange plastic secondary lock from the fuse block. Insert the terminal on the orange/white adapter wire until it stops. Refer to a nearby factory-installed terminal for comparison to verify proper orientation and depth. Install the secondary lock. | |||||||
7. | Cut excess length from the orange/white wire on the heated hand grip to within easy reach of the orange/white adapter wire installed in Step 8. | |||||||
WARNING Be sure to follow manufacturer's instructions when using the UltraTorch UT-100 or any other radiant heating device. Failure to follow manufacturer's instructions can cause a fire, which could result in death or serious injury. (00335a) | ||||||||
8. | Get the blue sealed splice connector (4) from the kit. Splice the orange/white wire from the heated hand grip power harness to the orange/white adapter wire per the service manual. NOTE
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9. | See Figure 8. Install a 2A fuse (13) from the kit into the P&A IGN fuse cavity to complete the circuit. Install the three fuses removed in Step 2 into the proper cavities. | |||||||
10. | Install the dust cover onto the fuse block. Install the fuse block. Install the main fuse holder per the service manual. | |||||||
11. | Open the cover of the fuse holder on the heated hand grip power harness. Plug the remaining 5A fuse (14) from the kit into the fuse holder. Close the cover. | |||||||
12. | Check along the entire length of the wiring for rubbing, chafing or pinch points. | |||||||
13. | Fasten the black wire with ring terminal to any ground stud on the frame. Proceed to COMPLETION. |
1. | See Figure 2. 2014-2015 Models: Verify that the shield (6) is in correct position on the outboard side of the switch module. a. Install the switch housing sections (4, 5) onto the switch module. Tighten captive screws (1) until snug. b. Install clutch control lever assembly (3). c. Install handlebar clamp (2) with two screws removed earlier, but do not tighten. d. Secure switch housing screws. Tighten. Torque: 4–5 N·m (35–44 in-lbs) e. Slide trigger finger switch cap (7) right to install. f. Tighten clutch handlebar clamp. Torque: 6.8–9 N·m (60–80 in-lbs) | |
NOTICE Do not route the handgrip main harness inside the switch housing. Wires routed inside the switch housing could result in short circuits and equipment damage. (00369a) | ||
2. | Route the heated hand grip main wire harness between the hand grip and left switch housing, then under the switch housing. | |
3. | See Figure 8. Are there holes on the left underside of the handlebar? a. If YES: Install wire retainer clips (12) from the kit in the holes. Fasten the wire harness to the clips. b. If NO: Use cable straps (9) to fasten the wire harness to the handlebar. |
1. | Obtain the new right side heated throttle grip (2) from the kit. Insert a screwdriver or other flat-blade tool between the body of the throttle grip and the end cap. Carefully pry the end cap off the grip. NOTE In the next step, DO NOT pull the plug from the throttle grip by grasping the wires or terminal pins. Only grasp the rubber tab on the plug. | |
2. | Tucked inside the outboard end of the throttle grip is a round rubber plug, with orange and green wires on one side and two pin terminals on the other. Using a needle-nose pliers or similar tool, carefully grasp the rubber tab on the wire side of the plug. Pull the plug out from the grip through the outboard opening. | |
3. | Thoroughly clean handlebar and inside of throttle grip to remove all dirt. | |
4. | NOTE
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5. | Install switch housings. Tighten screws until snug. | |
6. | Install brake control assembly, but do not tighten. | |
7. | Tighten switch housings. a. Push hand grip inboard to verify that hand grip is fully seated. b. Move the switch housing assembly inboard (away from grip) to remove all end play. Then move the switch housing outboard 1–2 mm (0.040–0.08 in) to introduce end play. c. While holding switch housing in place, tighten switch housing screws. Torque: 4–5.1 N·m (35–45 in-lbs) d. Verify that hand grip has slight inboard-outboard free play. e. Verify that hand grip rotates and returns freely. | |
8. | Secure brake control clamp screws. Tighten. Torque: 6.8–9.0 N·m (60–80 in-lbs) | |
9. | Again verify hand grip rotation and slight end play. | |
10. | See Figure 1 and Figure 2 , which show the similar left side housing installation. Install the right side handlebar controls in the same way. | |
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) | ||
11. | Verify that the right grip/throttle sleeve rotates and returns freely. The sleeve must not bind on the handlebar or switch housing. NOTE The terminal sockets on the twist grip sensor are offset to one side. The pins can only be inserted one way. | |
12. | Using a needle-nose pliers or similar tool, carefully grasp the tab on the wire side of the round rubber plug at the outboard end of the throttle grip. a. Insert the plug back through the opening in the grip. Insert the terminal pins into the sockets at the end of the twist grip sensor. b. Press the rubber plug firmly to verify that the pins are fully seated in the sockets. | |
13. | Install the chrome end cap onto the end of the throttle grip. |
1. | Follow instructions in the Electrical Connection Harness Kit to: a. Splice the orange/white wire in the hand grip kit to the violet/blue wire on the Electrical Connection Harness. b. Splice the red wire in the hand grip kit to the red/blue wire on the Electrical Connection Harness. c. Splice the black wire in the hand grip kit to the black wire on the Electrical Connection Harness. d. Install cap into 4-way pin side of connector if not used. e. Heat-shrink the sealed splices. f. Fasten the black wire with ring terminal to any ground stud on the frame. Proceed to COMPLETION. |
1. | Locate the Digital Technician connector [91A] (a gray six-way Deutsch pin connector with a rubber boot) under the seat. Place the Electrical Connection Harness at connector [91A], but DO NOT connect now. | |
2. | Route the heated hand grip wires over to the Electrical Connection Harness. DO NOT cut off the in-line fuse holder on the red wire, but cut the wires to a suitable length to easily reach the sealed splice connectors on the Electrical Connection Harness. | |
3. | Splice the black hand grip wire to the black wires in the Electrical Connection Harness. | |
4. | Splice the orange/white hand grip wire to the red/yellow wires in the Electrical Connection Harness. | |
5. | Splice the red hand grip wire to the red/blue wires in the Electrical Connection Harness. | |
6. | Use a heat gun or suitable radiant-heating device to shrink the connector to the wires. | |
7. | Pull the rubber boot out from the gray Digital Technician pin connector [91A]. Cut the boot off the wires. | |
8. | Connect the socket housing of the Electrical Connection Harness to connector [91A]. | |
9. | Insert the rubber boot into the open pin connector of the Electrical Connection Harness. | |
10. | Loosen or remove the four screws holding the ECM to the mounting bracket. Route the Electrical Connection Harness under the ECM connector. Secure the four screws. Tighten. Torque: 5.1–6.2 N·m (45–55 in-lbs) | |
11. | Heat-shrink the sealed splices. | |
12. | Fasten the black wire with ring terminal to any ground stud on the frame. Proceed to COMPLETION. |
1. | Verify that the right grip/throttle sleeve rotates and returns freely. The sleeve must not bind on the handlebar or switch housing. DO NOT operate the vehicle unless the throttle functions properly. | |
2. | Verify handlebar rotates freely and fully from right to left without pulling on the wires. |
1. | Verify that the ignition switch is OFF. See the service manual to install the main fuse. | |
2. | Install the fuel tank per the service manual. Install any other vehicle components removed earlier per service manual or kit instructions. | |
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) | ||
3. | See the service manual to install the seat. NOTE
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4. | Before starting the vehicle, check that the hand grips are not producing heat. | |
5. | Start the engine. Check the hand grips at all settings for proper heating. Ensure hand grips do not produce heat in the off setting. |
1. | See Figure 1. Check for proper wire routing. The hand grip main harness must be routed outside of the switch housing. If the wires were routed internally, disassemble the left handlebar switch housing and inspect for pinched wires. If wires are pinched, replace the left side hand grip and repeat the installation process with the correct wire routing. | |
2. | Check the wire connections of the orange/white, red and black hand grip main wire harness wires. a. If a connection is damaged, loose or weak, repair the connection. Test the hand grips. b. If all connections are good, continue with the next step. |
3. | Remove the left grip from the handlebar. | |
4. | Disconnect the connector on the left grip from the right grip wire harness. | |
5. | Check continuity across the two connectors in the left grip. If the test shows continuity, the hand grips are functional. | |
6. | Remove the seat according to service manual instructions. | |
7. | Start the vehicle. | |
8. | Check for 12 VDC across the red and black wires of the hand grip main wire harness. a. If 12 VDC is not present across the wires, check the fuse (14) in the wire harness and replace it if blown. b. If 12 VDC is not present, replace the left grip and wire harness and test the hand grips. |
1 | Left hand grip |
2 | Heat control |
3 | Positive to main circuit breaker or battery + connector |
4 | Fuse |
5 | Positive to accessory power |
6 | Negative ground |
7 | Right hand grip |
Kit | Item | Description (Quantity) | Part Number |
---|---|---|---|
Kit 56047-08A Flame Heated Grips | 1 | Left-side heated grip | 56100-04B |
2 | Right-side heated throttle grip (includes Item 3) | 56048-08 | |
3 |
| 55940-08 | |
Kit 56049-08A Ironside Heated Grips | 1 | Left-side heated grip | Not Sold |
2 | Right-side heated throttle grip (includes Item 3) | Not Sold | |
3 |
| Not Sold | |
Kit 56196-08A Chrome and Rubber (Small Diameter) Heated Grips | 1 | Left-side heated grip | 56617-04B |
2 | Right-side heated throttle grip (includes Item 3) | 56615-08 | |
3 |
| 55950-08 | |
Kit 56512-08A Contoured Chrome and Rubber Heated Grips | 1 | Left-side heated grip | 56514-04B |
2 | Right-side heated throttle grip (includes Item 3) | 56513-08 | |
3 |
| 55949-08 | |
Kit 56828-08A Aileron Heated Grips | 1 | Left-side heated grip | Not Sold |
2 | Right-side heated throttle grip (includes Item 3) | Not Sold | |
3 |
| Not Sold | |
Kit 56926-08A Skull Collection Heated Grips | 1 | Left-side heated grip | 56927-05A |
2 | Right-side heated throttle grip (includes Item 3) | 56928-08 | |
3 |
| 55957-08 | |
Kit 56100027 Slipstream Collection Heated Grips | 1 | Left-side heated grip | 56100038 |
2 | Right-side heated throttle grip | 56100032 | |
3 |
| 56100024 | |
Kit 56100047 Streamliner Collection Heated Grips | 1 | Left-side heated grip | 56100049 |
2 | Right-side heated throttle grip | 56100050 | |
Kit 56100107 Airflow Collection Heated Grips | 1 | Left-side heated grip | 56100109 |
2 | Right-side heated throttle grip | 56100096 | |
Kit 56100253 Airflow Collection Heated Grips | 1 | Left-side heated grip | 56100286 |
2 | Right-side heated throttle grip | 56100096 | |
Kits 56100255, 56100412 Streamliner Collection Heated Grips | 1 | Left-side heated grip (Kit 56100255) | 56100285 |
Left-side heated grip (Kit 56100412) | 56100417 | ||
2 | Right-side heated throttle grip (Kit 56100255) | 56100050 | |
Right-side heated throttle grip (Kit 56100412) | 56100418 | ||
Kit 56100257 Contoured Chrome and Rubber Collection Heated Grips | 1 | Left-side heated grip | 56100288 |
2 | Right-side heated throttle grip | 56513-08 | |
Kit 26100258 Slipstream Collection Heated Grips | 1 | Left-side heated grip | 56100292 |
2 | Right-side heated throttle grip | 56100032 | |
Kit 56100260 Skull Collection Heated Grips | 1 | Left-side heated grip | 56100293 |
2 | Right-side heated throttle grip | 56928-08 | |
Kit 56100263 Flame Collection Heated Grips | 1 | Left-side heated grip | 56100296 |
2 | Right-side heated throttle grip | 56048-08 | |
Kit 56100267 Chrome and Rubber Collection (Small Diameter) Heated Grips | 1 | Left-side heated grip | 56100295 |
2 | Right-side heated throttle grip | 56615-08 | |
Kit 56100362 Willie G Skull Matte Black Heated Grips | 1 | Left-side heated grip | 56100369 |
2 | Right-side heated throttle grip | 56100370 | |
Items common to ALL Kits | 4 | Sealed splice connector (2) | 70586-93 |
5 | Ring terminal, #10 (2) | 9857 | |
6 | Ring terminal, 1/4 inch (2) | 9858 | |
7 | Ring terminal, 5/16 inch | 9859 | |
8 | Wire harness, extension | 69201703 | |
9 | Cable strap, black, 7.75 inches (197 mm) long | 10006 | |
10 | Wire, fuse block adapter | 70329-04 | |
11 | Wire harness, adapter | 70310-04 | |
12 | Clip, wire retainer (4) | 70345-84 | |
13 | Fuse, "mini" blade type, 2 Amp (gray) (for vehicle fuse block) | 54305-98 | |
14 | Fuse, "mini" blade type, 5 Amp (light tan) (for inline fuse holder) (NOTE: A 4 Amp fuse is permissible in this position) | 72331-95 | |
15 | Wire harness, throttle sensor | 69201713 |