SOFTAIL HANDLEBAR KITS

941005182025-01-24

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
55801579	Safety Glasses, Torque Wrench

(1) Tightening to torque value or other moderate tools and techniques required

KIT CONTENTS

Figure 1. Kit Contents: Handlebars

Table 2. Kit Contents: Handlebar Kits

	Verify that all contents are present in the kit before installing or removing items from vehicle.
	Item	Qty	Description	Part No.	Notes
	1	1	Handlebar	Not sold separately
Items mentioned in text
	A	1	Knurled pattern

GENERAL

Instruction sheet is also available electronically. To verify you are using the most current version available, do one of the following:

Go to h-d.com/isheets
Scan QR code in upper left corner of the instruction sheet

NOTE

This instruction sheet may have a Supplemental Video to assist installer in clarifying a certain part of the assembly. A linked video would be located at the end of this instruction sheet.

Models

For model fitment information, see the Parts and Accessories (P&A) Retail Catalog or the Parts and Accessories section of www.harley-davidson.com.

Contact Harley-Davidson Customer Support Center at 1-800-258-2464 (U.S. only) or 1-414-343-4056.

Installation Requirements

WARNING

Replace 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)

WARNING

Rider and passenger safety depend 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. (00333b)

NOTE

This instruction sheet references service manual information. A service manual for the year and model motorcycle is required for this installation and is available from:

A Harley-Davidson dealer.
H-D Service Information Portal, a subscription-based access available for most 2001 and newer models. For more information see Frequently ask questions about subscriptions.

These items are available at your local Harley-Davidson dealership.

Separate purchase of a Original Equipment (OE) glued left hand grip may be required.

Separate purchase of additional parts or accessories are required for proper installation of this handlebar kit. See Handlebar Fitment Guide/Installation Requirements.

PREPARE

WARNING

To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)

WARNING

When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a)

CAUTION

Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b)

WARNING

Contact 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

(00240e)

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)

NOTE

If DOT 4 brake fluid contacts painted surfaces, IMMEDIATELY flush area with clear water.

1.	Loosen or remove fuel tank. See service manual.
2.	Remove fairing or windshield assemblies (if equipped). See service manual. a. Do not damage finished surfaces.
3.	If brake line replacement is necessary per handlebar installation requirements document, drain brake fluid from front brake reservoir and brake lines. See service manual.

REMOVE

NOTICE

Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)

NOTE

Cover painted parts to protect finish.

4.	Remove OE Handlebar.
5.	Note front brake line routing and orientation of the banjo fittings. a. Disconnect and remove brake line if required. See service manual. b. Save banjo bolts and discard sealing gaskets.
6.	Disconnect upper clutch cable from clutch lever. See service manual. a. Disconnect upper clutch cable from adjuster. See service manual. b. Remove upper clutch cable from vehicle. NOTE Record wire routing and cable strap locations before removal. NOTE Before disconnecting the turn signal wiring, note the wire routing. DO NOT remove the wires from the handlebar switch connector housings under the fuel tank. DO NOT remove the wires from the Multilock connector housing under the fuel tank.
7.	Remove any plastic wiring retainer clips or cable straps retaining the handlebar control and turn signal wiring to the handlebars and to the harness junction connectors. a. Disconnect handlebar wiring. See service manual.
8.	Use tape to wrap connector ends from each individual harness to make separate leaders. a. Wrap each tight enough to enter the hole.
9.	Remove front brake master cylinder and clutch lever assemblies from handlebar. a. Remove attached turn signal lamps and mirrors, if needed.
10.	Remove wire harness from handlebar. a. Set handlebar control assemblies aside.
11.	Remove left side switch housing assembly and wire harness. See service manual.
12.	Remove hand grip and set it aside for installation to new handlebar, unless being replaced.
13.	Remove stock handlebar from handlebar risers. See service manual. a. Save hardware and riser parts for later installation.

NEW HANDLEBAR INTERNAL WIRING

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)

NOTE

String may be routed through handlebar, starting at wire entrance hole at grip and using compressed air at grip end to blow string through bar.

Guide strings (or thin wires) aids in routing of wire bundles through handlebar.

If required, harness extensions are applied to riser end of handlebar, not at hand controls. See Handlebar Installation Requirements document to determine if necessary.

If also routing with turn signal extensions, space the turn signal bundle several inches beyond initial connector bundle at thinnest section for easier routing.

1.	Stagger connectors so they are not in same locations along harness. a. See Figure 2. String a suitable cord (1) through handlebar. b. Tie cord to wire harness. c. Wrap tape (2) over harness. d. Tape should come to a taper (3) and be flexible to ease pulling through handlebar. e. Pull cord through bar to route wire bundle to proper exit point.
2.	Apply a light coat of liquid soap, window cleaner or all-purpose lubricant to right side switch wire bundle. For handlebars with narrow castings, holes may be provided to apply liquid inside of handlebar.
3.	See Figure 3. With handlebar placed on a smooth, soft surface, grip ends upward, gently feed right side switch wire bundle into opening on underside of new handlebar and toward the large opening in center of bar.
4.	Pull taped ends of wire bundle through the exit opening in center of handlebar. a. Bring switch housing into approximate final position. b. DO NOT fasten switch housing to handlebar now.
5.	Remove tape from ends of wire bundles.
6.	Check for electrical continuity between handlebar and each wire in the wire bundles. a. Continuity would indicate a short circuit, which would require examination of wires and routing in switch housing.
7.	If a harness extension is required, install after routing wires through handlebar.

1	Pull cord
2	Taped wire harness
3	Tapered end

Figure 2. Pull Cord and Wire Harness

1	Upper switch mounting screw
2	Keep wires clear of pinch-points near threaded post
3	Wire
4	Hole in handlebar
5	Center wiring hole

Figure 3. Switch Housing Wire Routing

INSTALL HANDLEBAR ASSEMBLY

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.

Handlebar

1.	See Figure 1. Install handlebar (1) to riser base. NOTE Ensure handlebar is centered and properly oriented. a. Route wire bundles down through upper fork bracket.
2.	Seat handlebar with knurled areas (A) centered on riser base. a. Install riser clamp and clamp screws, but do not fully tighten. b. Adjust handlebar angle. c. Uprights of handlebar run roughly parallel to the front forks.

TORQUE HANDLEBAR CLAMP

See Figure 4 and Refer to Table 3. Tighten screws in sequence. Service manual specifications are shown in table for applicable models.

Figure 4. Handlebar Clamp Fastener Positions (typical)

Table 3. Handlebar Torque Sequence and Specification

Model	Torque Sequence and Torque Specification
FXBB	A, B, C, D 32.5–37.9 N·m (24–28 ft-lbs)
FXLRS	A, B, C, D 32.5–37.9 N·m (24–28 ft-lbs)
FXBR	A, B, C, D 32.5–37.9 N·m (24–28 ft-lbs)
FXLRST	A, B, C, D 32.5–37.9 N·m (24–28 ft-lbs)
FLHC	D, C, A, B 32.5–37.9 N·m (24–28 ft-lbs)
FLFB	C, D, A, B 26.1–31.2 N·m (19–23 ft-lbs)

INSTALL HAND CONTROLS

1.	Install new (purchased separately) throttle control cables and a new (purchased separately) or OE right grip/throttle sleeve assembly. See service manual.
2.	Adjust position of switch housing and brake lever assembly on handlebar for rider comfort. Handlebar orientation rotation is pinned to a certain amount of allowable rotation. a. Brake master cylinder must be horizontally level while vehicle is on its jiffy stand, for brake bleeding. See service manual.
3.	Torque brake lever clamp screws. a. First secure upper brake lever clamp screws. b. Then secure lower brake lever clamp screws. c. Tighten. See service manual.
4.	Tighten right switch housing screws. See service manual.
5.	Verify that the right grip/throttle sleeve rotates and returns freely not binding 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 left end of new handlebar according to handlebar grip instruction sheet or the service manual.
7.	Adjust positions of switch housing and clutch lever assembly on handlebar for rider comfort. See service manual.
8.	Torque clutch lever clamp screws. a. First secure upper clutch lever clamp screws. b. Then secure lower clutch lever clamp screws. c. Tighten. See service manual.
9.	Torque left switch housing screws. a. First secure lower switch housing screws. b. Then secure upper switch housing screws. c. Tighten. See service manual.
10.	Install proper length clutch cable (purchased separately). See service manual. Clutch cable routing may vary from stock routing, depending on handlebar. It may be necessary to route clutch cable through fork bracket rather than around fork tube.

WARNING

Replace 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)

NOTICE

Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a)

11.	Carefully inspect new brake lines (purchased separately) for damage or defects. Replace if damaged.
12.	Install brake line. See service manual or instructions included with brake lines.
13.	Bleed brakes. See service manual.

ELECTRICAL RECONNECTION

1.	Follow routing noted in disassembly steps until handlebar control wires and turn signal wires reach main vehicle harness switch and signal wire connector housings.
2.	Install any required electrical extension harnesses (purchased separately) for hand controls and/or front turn signal harnesses.
3.	Connect all harness connectors. See service manual. a. Refer to routing and securing notes taken during harness removal.

COMPLETE

1.	Install fuel tank. See service manual.
2.	Install windshield or fairing, if removed. See service manual.

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 cable and brake lines do not pull tight when handlebars are turned fully to left or right fork stops.
Clutch cable and brake lines must not catch on headlamp hardware or pass in front of headlamp.
Clutch cable and brake lines must not catch on turn signal mounting hardware or turn signals.
Clutch cable and brake lines must not catch on fuel cap.
Clutch cable and brake lines must not catch on speedometer.
Make sure that clutch cable and brake lines are not pinched between the frame and/or forks.
Make sure that clutch cable 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.

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)

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)

NOTE

Verify that the ignition switch is in the OFF position before installing main fuse.

Install main fuse. See service manual.

2.	Push engine OFF/RUN/START switch to RUN to enable electrical system. See owner's manual. a. DO NOT press rocker switch completely down, this will start the engine.
3.	Turn handlebar to the left and right steering stops, testing handlebar control functions at each stop.
4.	Test all switches and lights for proper operation.
5.	Push engine OFF/RUN/START switch to OFF.
6.	Apply front brake hand lever to test operation of brake lamp.
7.	Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual.