ACCESSORY HANDLEBAR KIT
J064082017-08-23
GENERAL
Kit Numbers
55800712, 55800714, 55800715, 55800717, 58800719, 58800721
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 are required for proper installation of this handlebar kit. See the P&A retail catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for this model.
Motorcycles equipped with a glued left side hand grip 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.
NOTE
This instruction sheet refers to service manual information. A service manual for this year/model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Kit Contents
PREPARATION
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
ORIGINAL HANDLEBAR REMOVAL
NOTE
Cover painted parts to protect finish.
Remove the windshield, if equipped.
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
1.
Note the front brake line routing and the orientation of the banjo fittings. See the service manual. Disconnect and remove the brake line. Save the banjo bolts, but discard the sealing gaskets.
2.
See the service manual and disconnect the clutch cable from the clutch lever. Disconnect the clutch cable from the side cover. Remove the cable from the vehicle.
NOTE
Record wire routing and cable strap locations before removal.
Refer to the correct connector section in the service manual appendix for disconnection procedures.
3.
Remove and discard any plastic wiring retainer clips and cable straps retaining the handlebar control and turn signal wiring from the handlebars to the harness junction connectors. Refer to the correct connector section in the service manual appendix to disconnect the handlebar wiring.
4.
Note the wire colors and positions in each cavity of the connector housings leading from the switches and from the turn signals. Refer to the correct connector section in the service manual appendix to remove the wires from the housings.
5.
Use tape to wrap the wire terminal ends from each individual harness to make separate leaders. Wrap each leader tight enough to pass easily through the new handlebars.
6.
Remove the front brake master cylinder and clutch lever assemblies from the handlebar. Remove the attached turn signal lamps and mirrors, if needed.
7.
Remove the wire harness from the handlebar. Set the handlebar control assemblies aside.
8.
Remove the twist grip sensor from the handlebar. Unless being replaced, remove the right grip/throttle sleeve and set it aside for installation to the new handlebar.
9.
See the service manual for removal of the left side switch housing assembly and wire harness.
10.
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, unless being replaced.
11.
See the service manual. Remove stock handlebar from the handlebar risers. Save hardware and riser parts for later installation.
NEW HANDLEBAR INTERNAL WIRING
1.
Unless already done, remove any cable straps and plastic wiring retainer clips that secured the switch harnesses to the OE handlebar.
2.
If not already done, use tape to wrap the wire terminal ends from each source to make separate leaders. Wrap each leader tight enough to enter the grommet opening and pass easily through the new handlebar.
3.
Label each wire bundle (left or right) to help make sure that wires are routed properly.
NOTE
Guide strings (or thin wires) may aid in the routing of the wire bundles through the handlebar.
4.
See Figure 1. Stagger the pins (1) so they are not in the same locations along the harness (2). See Figure 2. String a suitable cord (1) through the handlebar. Tie the cord to the wire harness. Wrap tape (2) over the harness and pins. Tape should come to a taper (3) and be flexible to ease pulling through the handlebar. Pull the cord through the bar to route the wire bundle to the proper exit point.
1Pins
2Wire harness
3Two pin heated hand grip harness
Figure 1. Pins and Wire Harness
1Pull cord
2Taped wire harness
3Tapered end
Figure 2. Pull Cord and Wire Harness
5.
Apply a light coat of liquid soap, or all-purpose lubricant to the right side switch wire bundle.
6.
See Figure 3. With the handlebar placed on a smooth, soft surface, grip ends upward, gently feed the right side switch wire bundle into the opening on the underside of the new handlebar and toward the large opening in the center of the bar.
WARNING
Carefully pull the wires through hole in handlebar to prevent stripping the wires. Stripped wires can cause short circuits and damage vehicle electrical components, which could cause loss of vehicle control resulting in death or serious injury. (00418b)
7.
Pull the taped ends of the wire bundle through the exit opening in the center of the handlebar. Bring the switch housing into approximate final position. DO NOT fasten the switch housing to the handlebar now.
8.
Repeat Steps 4 through 6 with the left side switch wire bundle, and both turn signals, if needed.
1Center wiring hole
2Upper switch mounting screw
3Lower switch mounting screw
4Position inside switch edge pinch-point above wires and hole in handlebar
5Keep wires clear of pinch-points near threaded post
Figure 3. Switch Housing Wire Routing
9.
Remove the tape from the ends of the wire bundles.
10.
Check for electrical continuity between the handlebar and each wire in the wire bundles. Continuity would indicate a short circuit, which would require examination of the wires and routing in the switch housing.
Handlebar Installation
NOTE
Typical handlebar orientation places the handlebar riser plane parallel to the front forks of the vehicle. State or local regulations may dictate handlebar height limits. Research and adjust accordingly.
1.
See Figure 4. Install the handlebar (1) to the riser base, routing the wire bundles down through the upper fork bracket.
2.
Seat the handlebar with the knurled areas (A) centered on the riser base. Install the riser clamp and clamp bolts, but do not fully tighten.
3.
Adjust handlebar angle. The uprights of the handlebar run roughly parallel to the front forks.
NOTE
Tighten the front pair of riser screws first, then the rear riser screw pair.
4.
With the handlebar centered and oriented, tighten the riser clamp fasteners. Tighten.
Torque: 16.3–21.7 N·m (12–16 ft-lbs)
Hand Control and Switch Wire Housing Installation
1.
See service manual. Install the new (purchased separately) throttle control cables and a new (purchased separately) or OE right grip/throttle sleeve assembly.
2.
Adjust the position of the switch housing and the brake lever assembly on the handlebar for rider comfort. The brake master cylinder must be horizontally level while the vehicle is on its jiffy stand, for brake bleeding.
3.
Tighten first the top. Then tighten the bottom brake lever clamp screws. Tighten.
Torque: 6.7–9 N·m (60–80 in-lbs)
4.
Tighten first the lower. Then tighten the upper switch housing screws. This leaves any gap in the switch housing at the front for best appearance. Tighten.
Torque: 4–5.1 N·m (35–45 in-lbs)
5.
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.
6.
Install a new (purchased separately) or OE handlebar grip on the left end of the new handlebar according to the handlebar grip instruction sheet or the service manual.
7.
See service manual. Adjust the positions of the switch housing and the clutch lever assembly on the handlebar for rider comfort.
8.
Tighten first the top. Then tighten the bottom clutch lever clamp screws. Tighten.
Torque: 6.7–9 N·m (60–80 in-lbs)
9.
Tighten first the lower. Then tighten the upper switch housing screws. Tighten.
Torque: 4–5.1 N·m (35–45 in-lbs)
10.
Refer to the service manual and follow the instructions to install a proper length clutch cable (purchased separately).
11.
Carefully inspect the new brake lines (purchased separately) for damage or defects, and replace if damaged. Install the brake line per service manual instructions or the instructions included with the brake lines.
12.
Bleed the brakes per the instructions in the service manual.
ELECTRICAL RECONNECTION
  1. Follow the routing noted in the disassembly steps until the handlebar control wires and turn signal wires reach the main vehicle harness switch and signal wire connector housings.
  2. Refer to the notes taken during installation. See service manual. Install the pins into the connector pin housings.
  3. Install any required electrical extension harnesses (sold separately)for hand controls and/or front turn signal harnesses. Refer to the installation instructions for those kits.
  4. Refer to the notes taken during removal and the service manual and connect all harness connectors.
  5. See Figure 4. Install hole plugs (2) into the handlebar. Make sure to align the logo.
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)
  • Verify wires, clutch cables, throttle/idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops.
  • Lines must not catch on headlamp hardware or pass in front of headlamp.
  • Lines must not catch on turn signal mounting hardware or turn signals.
  • Lines must not catch on fuel cap.
  • Lines must not catch on speedometer.
  • Make sure that lines are not pinched between the frame and/or forks.
  • Make sure that clutch line does not pull tight when handlebar is turned fully to left or right fork stops.
  • Make sure control wires/jumpers do not pull tight when handlebars are turned fully to left or right fork stops.
NOTE
Verify that the ignition switch is in the OFF position before attaching the main fuse.
1.
Refer to the service manual. Install main fuse.
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 switch to IGNITION, but do not start the motorcycle. Test all switches and lights 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
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
Figure 4. Service Parts: Handlebar
Table 1. Service Parts
Kit
Item
Description (Quantity)
Part Number
55800712
1
Handlebar, 1.25 inch reach, chrome
Not sold separately
55800714
1
Handlebar, 1.25 inch reach, black
Not sold separately
55800715
1
Handlebar, 1 inch reach, chrome
Not sold separately
55800717
1
Handlebar, 1 inch reach, gloss black
Not sold separately
55800719
1
Handlebar, 1 inch tallboy, chrome
Not sold separately
55800721
1
Handlebar, 1 inch tallboy, gloss black
Not sold separately
Items mentioned in text.
A
Knurled pattern