ACCESSORY HANDLEBAR KITS
J0060722015-06-30
GENERAL
Kit Number
55800421, 55800422
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 and installation of extra parts or accessories may be required for proper installation of this kit on your model motorcycle. 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.
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 Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333a)
NOTE
This instruction sheet references service manual information. A service manual for your model motorcycle is required for this installation. One is available from a Harley-Davidson dealer.
Kit Contents
Table 1. Kit Contents
Description (Quantity)
Part Number
Handlebar
Not Sold Separately
Plug, chrome (2) (Kit 55800421)
55900075
Plug, black (2) (Kit 55800422)
55900076
INSTALLATION
This handlebar installs in the same manner as the original equipment (OE) handlebar, except for internal handlebar wire routing. See the service manual to remove and install the handlebar. See Internal Handlebar Wiring below for wire routing instructions.
Internal Handlebar Wiring
1.
Models with heated hand grip wiring: Cut and remove the unused heated hand grip two-pin connectors from both ends of the harness.
2.
Wrap wire terminal ends from each source in tape to make separate leaders. Wrap each leader tight enough to enter 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) aids 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
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, window cleaner 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 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 3 through 5 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
6Wiring access
7Access hole plug
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 indicates a short circuit, which requires examination of the wires and routing in the switch housing.
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)
  • 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.
1.
Verify that the ignition/light key switch is turned to OFF. 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/light key switch to IGNITION, but do not start the engine. Test all switches and lights for proper operation.
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)