1. | See Figure 1. At the top frame tube (1), remove the right (2) and left (3) side grommets to access the turn signal connectors. |
Figure 1. Top Frame Tube Access Location | ||||||
2. | Locate the right turn signal connector and carefully pull it out of the right side of the top frame tube access hole. Repeat for left side turn signal connector. | |||||||
3. | Disconnect both right and left turn signal connectors from harness. Follow procedure in the service manual to remove right and left turn signal wires from connectors. | |||||||
4. | Using a 4-foot piece of heavy duty wire or mechanics wire, wrap turn signal wires with electrical tape in preparation of pulling wires through handlebars (FXDWGI models) and lower housing. NOTE Do not pull turn signal wires at this time. The procedure for disassembling the right and left switch housing must be completed first. |
1. | See Figure 2. Place an insert (cardboard or cable strap eyelet) (1) between brake lever and lever bracket to prevent damage to rubber boot and plunger during master cylinder disassembly. | |||||||
2. | Remove two screws with flat washers securing handlebar clamp to master cylinder housing. |
Figure 2. Brake Lever / Lever Bracket Cardboard Insert | ||||||
3. | Remove upper and lower switch housing screws. | |||||||
4. | Remove brake lever/master cylinder assembly and clamp from handlebar. | |||||||
5. | Remove friction shoe from end of tension adjuster screw on all models with adjuster. NOTE The friction shoe is a loose fit and may fall out or become dislodged if the lower switch housing is turned upside down or shaken. | |||||||
6. | Turn cable adjusters all of the way in to create slack in cables. Unhook throttle and idle return control cable brass ferrules from notches on inboard side of throttle control grip. Remove ferrules from cable end fittings. | |||||||
7. | Remove throttle control grip. | |||||||
8. | See Figure 3. Pull crimped inserts, at end of throttle (3) and idle (2) control cable housings from lower switch housing (1). For best results, use a rocking motion while pulling. Place a drop of light oil on retaining rings, if necessary. Remove cables from switch housing. |
Figure 3. Idle/Throttle Control Cable Connections to Switch Housing |
1. | Remove Phillips-head screw from housing. | |
2. | Remove switch bracket and switch assembly from housing. NOTE Lightly lubricate turn signal wires and electrical tape with glass cleaner to help prevent wires from binding as they are being pulled through lower housing and handlebar. | |
WARNING Grommets in each of the wiring holes in the handlebar must remain in position after routing the wiring through the handlebar. Operation without the grommets in place can damage wires, causing a short circuit which could result in death or serious injury. (00416d) | ||
3. | For FXDWGI and FXDBI Models: With the switch housing removed from the handlebar, pull right turn signal wires (with heavy-duty wire or mechanics wire attached) out of handlebar (FXDWGI models). Pull wires out of the bottom of the lower switch housing. |
1. | See Figure 4. Carefully cut the cable strap (2) holding the wire conduit to the turn signal switch bracket. | |||||||||||||||||||||||||||||
2. | Remove Phillips head screw (1) near securing bracket at center of housing. NOTE It may be necessary to pull back vinyl conduit on harness to put slack in wires so the turn signal switch and bracket can be removed. | |||||||||||||||||||||||||||||
3. | Lift bracket and turn signal switch from housing. |
Figure 4. Lower Right Side Handlebar Switch Cable Strap | ||||||||||||||||||||||||||||
4. | See Figure 5. To remove the brake light switch (2) and wedge (4): a. Gently pry out wedge located between switch housing (1) and brake light switch (2). Save the wedge for assembly. b. Gently push the brake light switch into the switch housing with thumb. Gently pull up on the brake light switch assembly while rotating and rocking it slightly. c. Inspect brake light switch rubber boot for damage. If necessary, replace damaged brake light switch. NOTE For Lower Switch Housings with Radio Tuning and/or Cruise Control only: Follow Steps 5-8. | |||||||||||||||||||||||||||||
5. | See Figure 6. Use the short end (4) of the keycap removal tool (1) to remove the cruise control (RES/SET) keycap (2). Push up under the keycap. NOTE The cruise control keycap must be removed before attempting to remove the mode select keycap. | |||||||||||||||||||||||||||||
6. | Remove the mode select keycap (3) using the long end of the keycap removal tool (5). Insert the tool under the keycap and push tool outward until keycap is disengaged from the switch pin ( Figure 7 , item 2). | |||||||||||||||||||||||||||||
7. | Remove two screws holding lower bracket to boss in housing. Pull bracket from switch housing. | |||||||||||||||||||||||||||||
8. | Mark or note the positions (top, right, left) of the radio and/or cruise control switches and remove the switch assemblies. |
Figure 5. Brake Light Switch
Figure 6. Right Handlebar Lower Switch Housing Keycap Removal
Figure 7. Lower Switch Housing Keycap Removal |
1. | Remove Phillips-head screw. | |
2. | Remove horn and high/low beam switch assemblies and bracket from housing. NOTE Lightly lubricate turn signal wires and electrical tape with glass cleaner to help prevent wires from binding as they are being pulled through handlebar. | |
WARNING Grommets in each of the wiring holes in the handlebar must remain in position after routing the wiring through the handlebar. Operation without the grommets in place can damage wires, causing a short circuit which could result in death or serious injury. (00416d) | ||
3. | For FXDWGI Models: With the switch housing removed from the handlebar, pull left turn signal wires (with fish wire attached) out of handlebar. Pull wires out of the bottom of the lower switch housing. |
1. | See Figure 8. Carefully cut the cable strap holding the wire conduit to the turn signal switch bracket (1). | |||||||||||||||||||||||
2. | Remove the screw holding upper bracket from the housing (3). | |||||||||||||||||||||||
3. | Lift bracket and turn signal switch from housing. Turn signal keycap is not removable. |
Figure 8. Models with Radio and CB - Left Handlebar Lower Switch Housing Assembly | ||||||||||||||||||||||
4. | See Figure 9. Remove the SQ-/PTT/SQ+ keycap (2) using the short end (4) of the keycap removal tool (1). Push up under the keycap (2). The tool taper will slowly push the keycap off of the switch pin. NOTE The SQ-/PTT/SQ+ keycap must be removed before removing the audio control keycap. | |||||||||||||||||||||||
5. | Remove the audio control keycap (3) using the long end (5) of the keycap removal tool ( Figure 7 , item 1). Insert the tool under the keycap and push tool out until keycap is disengaged from the switch pin (2). | |||||||||||||||||||||||
6. | See Figure 8. Remove two screws holding lower bracket (7) to boss in housing. Pull bracket from switch housing. | |||||||||||||||||||||||
7. | Mark or note the positions (top, right, left) of the radio (2) and/or PTT (5) switches and remove the switch assemblies. |
Figure 9. Left Handlebar Lower Switch Housing Keycap Removal Tool |
1. | See Figure 11. Place cruise control (1) and/or radio (4) switches into chrome lower housing cavity (6). Properly installed, the switches lay in blocks cast into the lower cavity. The cruise control switch lays on edge and operates in a horizontal position. Verify that the switch shaft is aligned for proper keycap operation. | |||||||||||||||||||||||||||||||||
2. | Place the lower bracket (7) into the housing (weld nut side down). On cruise control models: Lower step of bracket should be positioned over cruise control switch (1) (horizontally oriented). Slots in upper step engage two tabs on body of radio control switch (4). | |||||||||||||||||||||||||||||||||
3. | Install longer screw into front of lower bracket (7) and into threaded boss in housing. | |||||||||||||||||||||||||||||||||
4. | Place shorter screw through rear of lower bracket and into threaded boss in housing. |
Figure 10. Upper Right Handlebar Switch Housing
Figure 11. Right Handlebar Lower Switch Housing | ||||||||||||||||||||||||||||||||
5. | See Figure 5. Install brake light switch (2) and wedge (4): Carefully press plunger against inside wall of the switch housing. With thumb over plunger bore, move switch into the installed position in the switch housing cavity (5). When plunger is positioned against thumb, slowly rotate switch downward while rocking slightly. Release the plunger only after switch is properly positioned in the cavity. Verify that the plunger is square in the bore and that the boot is not compressed, collapsed or torn. If necessary, gently move the plunger in and out until boot is fully extended. | |||||||||||||||||||||||||||||||||
NOTICE If routed incorrectly, wires can be pinched by casting or handlebar resulting in switch failure. (00542b) | ||||||||||||||||||||||||||||||||||
6. | Push down on switch so that it bottoms against housing and wires run in groove (6) at base of cavity. With the concave side facing outward, insert wedge between switch and outboard side of switch housing. Push wedge down until it bottoms against housing. Verify that the plunger is still square in the bore and then place a drop of silicone sealant on upper corner of wedge. | |||||||||||||||||||||||||||||||||
7. | To connect the upper bracket to the housing: See Figure 4. Insert the tapered end of a new cable strap into the rear, right side, round hole in turn signal switch bracket. Feed the strap back through the front, right side hole. The oblong hole is for the bracket screw. Install turn signal switch into chrome housing. Align the oblong hole in the bracket with the threaded hole in the lower bracket weld nut. Be sure the bracket is fully seated. Tabs on each side of bracket are captured in slots cast into switch housing. | |||||||||||||||||||||||||||||||||
8. | Start upper bracket Phillips-head screw into housing. | |||||||||||||||||||||||||||||||||
9. | Tighten Phillips-head screw. | |||||||||||||||||||||||||||||||||
10. | Capturing conduit about 1/4 inch (6.3 mm) from end, securely tighten cable strap to draw conduit to bracket. Remove any excess cable strap material. | |||||||||||||||||||||||||||||||||
11. | Route wire bundle to upper switch housing, below and then forward of the main harness positioning conduit in channel next to angular arm of bracket. |
1. | For FXDWGI and FXDBI Models: Feed right side turn signal wires (with fish wire attached) through the right side chrome lower switch housing hole at bottom of housing. For FXDWGI Models: Feed turn signal wires into handlebar opening. Continue feeding wires through handlebar and out the center hole opening. Feed wires through down and into top frame tube. | |||||||||||||
2. | Remove fish wire from turn signal wires. Insert wires into right turn signal connector. Refer to the service manual for electrical connections procedure. | |||||||||||||
3. | See Figure 3. Connect throttle (3) and idle (2) control cables to the lower switch housing (1): Push throttle and idle control cables into lower switch housing until they snap in place. Push larger diameter (5/16 inch [7.9 mm]) throttle cable into larger hole, in front of tension adjuster screw. Push smaller diameter (1/4 inch [6.3 mm]) idle cable housing into smaller hole, at the rear of tension adjuster screw. NOTE To aid assembly, apply a drop of light oil on the retaining rings of the crimped inserts. Always replace the retaining rings if damaged or distorted. | |||||||||||||
4. | With lower switch housing concave side facing up, install friction shoe so that pin hole is over point of the adjuster screw, if fitted. NOTE The friction shoe is a loose fit and may fall out or become dislodged if the switch housing is turned upside down or shaken. |
Figure 12. Throttle / Idle Cable Connections in Grip | ||||||||||||
5. | See Figure 12. Slide throttle control grip (1) over end of right handlebar until it bottoms against the closed end. Rotate grip so that ferrule notches (6) are at top. | |||||||||||||
6. | Position lower switch housing beneath throttle control grip. Place a brass ferrule onto throttle (2) and idle (3) cables so that end fittings seat in ferrule (6) recess. Seat ferrules in their respective notches (5) on throttle control grip (1). Verify that cables are captured in grooves (4) molded into grip. | |||||||||||||
7. | To prevent binding, pull the grip back about 1/8 inch (3.2 mm). | |||||||||||||
8. | Position upper switch housing over handlebar and lower switch housing. | |||||||||||||
9. | Verify that wire conduit is in the depression at the bottom of the handlebar. Be sure conduit will not be pinched under handlebar when switch housing screws are tightened. | |||||||||||||
10. | Start upper and lower switch housing screws. Do not tighten. | |||||||||||||
NOTICE Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) | ||||||||||||||
11. | See Figure 13. Position brake lever/master cylinder assembly inboard of the switch housing assembly. Engage the tab on lower switch housing in groove at top of brake lever bracket. | |||||||||||||
12. | Align holes in handlebar clamp with holes in master cylinder housing. Start the two screws (with flat washers). Position for rider comfort. Beginning with the top screw, tighten screws to 6.8–9 N·m (60–80 in-lbs). | |||||||||||||
13. | Tighten lower and upper switch housing screws to 3.9–5.5 N·m (35–45 in-lbs). NOTE Always tighten the lower switch housing screw first so that any gap between the upper and lower housings is at the front of the switch. | |||||||||||||
14. | Remove the insert between the brake lever and lever bracket. | |||||||||||||
15. | Test switches for proper operation. | |||||||||||||
16. | Note lettering for proper orientation and gently push keycaps onto switch shafts. |
Figure 13. Brake Lever/Master Cylinder Fit to Right Handlebar Lower Switch Housing |
1. | For FXDWGI and FXDBI Models: Feed left side turn signal wires (with fish wire attached) through the left side chrome lower switch housing hole at bottom of housing. For FXDWGI Models: Feed turn signal wires into handlebar opening. Continue feeding wires through handlebar and out the center hole opening. Feed wires down and into top frame tube. | |||||||||||
2. | Remove fish wire from turn signal wires. Insert wires into left turn signal connector. Refer to the service manual for electrical connections procedure. | |||||||||||
3. | See Figure 14. Place upper (1) and lower (2) switch housings on handlebar. Be sure that ribs (3) on outboard side of both switch housings fit in grooves (4) molded into grip (5). | |||||||||||
4. | Verify that wire conduit is in depression at bottom of handlebar. Be sure conduit will not be pinched under handlebar when switch housing screws are tightened. | |||||||||||
5. | Start upper and lower switch housing screws, but do not tighten. |
Figure 14. Left Handlebar Switch Housings | ||||||||||
6. | Position clutch hand lever assembly inboard of switch housing assembly. See Figure 15. Engage tab (2) on lower switch housing (1) with groove (4) at bottom of clutch lever bracket (3). | |||||||||||
7. | Align holes in handlebar clamp with holes in clutch lever bracket. Start the two screws (with flat washers). Position this assembly for rider comfort. | |||||||||||
8. | Beginning with top screw, tighten screws to 6.8–9 N·m (60–80 in-lbs). | |||||||||||
9. | Tighten lower and upper switch housing screws to 3.9–5.5 N·m (35–45 in-lbs). NOTE Always tighten lower switch housing screw first so that any gap between upper and lower housings is at the front of the switch. | |||||||||||
10. | Connect right and left turn signal connectors to wire harness connectors. Place both connectors inside top frame tube. | |||||||||||
11. | See Figure 1. Install the left (3) and right (2) side top frame tube grommets into top frame tube. |
Figure 15. Clutch Lever Bracket Fit to Left Handlebar Switch Housing |
Item | Description (Quantity) | Part Number |
---|---|---|
Kit number 70222-96B - Chrome Switch Housing, Sport | ||
1 | Chrome switch housing, lower right | 71719-03 |
2 | Chrome switch housing, lower left | 71720-03A |
3 | Chrome switch housing, upper right | 71614-96 |
4 | Chrome switch housing, upper left | 71615-96 |
5 | Cable tie (2) | 10181 |
6 | Screw, socket button head 1/4-20 x 1-1/8 inch (4) | 4292 |
Kit number 70223-96B - Chrome Switch Housing, Classic | ||
1 | Chrome switch housing, lower right | 71556-96 |
2 | Chrome switch housing, lower left | 71611-96A |
3 | Chrome switch housing, upper right | 71614-96 |
4 | Chrome switch housing, upper left | 71615-96 |
5 | Cable tie (2) | 10181 |
6 | Screw, socket button head 1/4-20 x 1-1/8 inch (4) | 4292 |
7 | Keycap removal tool | Not Sold Separately |
Kit number 70228-96C - Chrome Switch Housing, Ultra | ||
1 | Chrome switch housing, lower right | 71612-96 |
2 | Chrome switch housing, lower left | 71613-96B |
3 | Chrome switch housing, upper right | 71614-96 |
4 | Chrome switch housing, upper left | 71615-96 |
5 | Cable tie (2) | 10181 |
6 | Screw, socket button head 1/4-20 x 1-1/8 inch (4) | 4292 |
7 | Keycap removal tool | Not Sold Separately |
Kit number 71813-09 - Chrome Switch Housing, FLHX/FLHT/FLHTC with Cruise Control | ||
1 | Chrome switch housing, lower right | 71612-96 |
2 | Chrome switch housing, lower left | 71611-96A |
3 | Chrome switch housing, upper right | 71614-96 |
4 | Chrome switch housing, upper left | 71615-96 |
5 | Cable tie (2) | 10181 |
6 | Screw, socket button head 1/4-20 x 1-1/8 inch (4) | 4292 |
7 | Keycap removal tool | Not Sold Separately |