1 | Handlebar |
2 | Throttle twist grip sensor |
3 | Seal cap |
1 | Heat shrink tubing |
2 | 2008-2009 stock jumper harness |
1 | TGS main harness connector |
2 | Right side heated hand grip connector (to left side hand grip) |
3 | To TGS |
4 | To TGS heated grip wires |
1. | 2008 and 2009 Models: Thread the twist grip sensor wire harnesses into the right side of the handlebar. a. While feeding the wiring into the handlebar, gently pull the connectors at the end of the jumper harness to draw the twist grip sensor out the center of the handlebar. b. Fit the index tabs on the twist grip sensor into the slots in the handlebar. One index tab and slot are smaller than the others to prevent improper assembly. | |||||||||||
2. | ALL Models: Thread the left side heated grip wire harness all the way through and out the center of the handlebar. Some models may require an additional jumper to reach from the left side grip to the mating connector on the twist grip sensor (depending on handlebar height, vehicle model and year). See Figure 10. This 14 in. jumper with black/white wires is provided in the kit. NOTE Make sure that the handlebar surface is smooth, dry and thoroughly cleaned of all dirt. NOTE Before pulling wire through handlebars, run wire alongside handlebar to determine if an extension is needed. If an ADDITIONAL extension is needed, see parts list. Some internally wired handlebars, like chiseled or models with handlebar mounted turn signals, de-pinning the heated grip connector may be required. Take a photo of all connectors for re-assembly prior to de-pinning. To aid in pulling, spray or rub with soapy water. | |||||||||||
3. | See Figure 4. Position the left side heated grip (4) so the larger diameter portion of the flange (5) is at the bottom. Push the grip fully onto the handlebar. | |||||||||||
4. | Position the lower switch housing beneath the grip so that the grooves (2) on the outboard side of the switch housing fit over the flange on the end of the grip. | |||||||||||
5. | Position the upper switch housing over the handlebar and lower switch housing. | |||||||||||
6. | 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. | |||||||||||
7. | Position the clutch hand-lever assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the clutch lever bracket. | |||||||||||
8. | Align the hole in the handlebar clamp with the hole in the clutch lever bracket, and start the lower screw with flat washer. Adjust the switch housing and clutch hand control position for rider comfort. | |||||||||||
9. | Using a T-27 TORX drive head, tighten first the upper, then the lower handlebar clamp screws to. Tighten. Torque: 6.8–9 N·m (60–80 in-lbs) clamp screws | |||||||||||
10. | Using a T-25 TORX drive head, tighten first the lower, then the upper switch housing screws to. Tighten. Torque: 4–5.4 N·m (35–45 in-lbs) switch housing screws |
Figure 4. Left Handlebar Switch Housing | ||||||||||
11. | Obtain the new right side heated throttle grip (2) from the kit. | |||||||||||
12. | Tucked inside the outboard end of the throttle grip is a round plastic plug, with two-pin terminals on one side. Carefully pull the plug out from the grip through the outboard opening. NOTE Make sure that the handlebar surface and the inside of the new throttle grip are smooth, dry and thoroughly cleaned of all dirt. | |||||||||||
13. | Slide the new heated throttle grip over the end of the handlebar. Rotate the grip to verify that the internal splines are engaged with those on the twist grip sensor. | |||||||||||
14. | Refer to Figure 4 , which shows the similar left side switch mounting. Position the lower switch housing beneath the grip so that the grooves (2) on the outboard side of the switch housing fit over the flange on the end of the grip. | |||||||||||
15. | Position the upper switch housing over the handlebar and lower switch housing. | |||||||||||
16. | 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. | |||||||||||
17. | Position the brake master cylinder housing inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the bottom of the master cylinder housing. | |||||||||||
18. | Align the hole in the handlebar clamp with the hole in the master cylinder housing, and start the lower screw with flat washer. Adjust the switch housing and brake hand control position for rider comfort. | |||||||||||
19. | Using a T-27 TORX drive head, tighten first the upper, then the lower handlebar clamp screws. Tighten. Torque: 6.8–9 N·m (60–80 in-lbs) clamp screws NOTE Do not pull the switch housing so far inboard as to cause the throttle grip to bind or drag on the handlebar. Actuate the throttle grip to verify that it freely returns to the idle position. | |||||||||||
20. | Using a T-25 TORX drive head, tighten first the lower, then the upper switch housing screws. Tighten. Torque: 4–5.4 N·m (35–45 in-lbs) switch housing screws | |||||||||||
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) | ||||||||||||
21. | Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing. NOTE The terminal sockets on the twist grip sensor are offset to one side, and the pins can only be inserted one way. | |||||||||||
22. | Using a needle-nose pliers or similar tool, carefully grasp the round plastic plug at the outboard end of the throttle grip. a. Insert the plug back through the opening in the grip, and insert the terminal pins into the sockets at the end of the twist grip sensor, engaging the two legs of the plug into the throttle grip sensor openings. b. Press the plastic plug firmly to verify that the pins are fully seated in the sockets. | |||||||||||
23. | Install the end cap onto the end of the throttle grip. |
1 | Interconnect connector |
2 | Twist grip sensor jumper harness connector |
3 | Heated hand grip power connector |
1 | TGS jumper harness connector |
2 | Front fender tip lamp jumper harness connector |
1 | Stripped wire ends inserted into connector |
2 | Wire ends crimped in connector |
3 | Connector after heat has been applied |
1 | Heated Grip Connector (insert jumper 69201809 if needed) |
2 | Power/Ground Connector |
3 | Jumper 69201808 (Softail, Dyna, Road King and FLTRU) |
4 | Adapter Harness 69200232 |
5 | Heated Grip Connector [C189B] |
6 | Electrical Connection Kit: (All Black to Black) 69200722, 69201599A V/BE to Red, 72673-11 R/Y to Red, 69201750 use connector |
7 | Vehicle Harness |
8 | Twist Grip Sensor Connector |
9 | Twist Grip Sensor |
10 | LH Grip |
11 | RH Grip |
Kit | Item | Description (Quantity) | Part Number |
---|---|---|---|
Kit 56100034 | 1 | Left heated hand grip | 56209-10 |
2 | Right heated hand grip | 56249-10 | |
3 | Right heated hand grip cap | 56250-10 | |
Kit 56100318 | 1 | Left heated hand grip | 56100325 |
2 | Right heated hand grip | 56100326 | |
3 | Right heated hand grip cap | 56100329 | |
Kit 56100331 | 1 | Left heated hand grip | 56100338 |
2 | Right heated hand grip | 56100339 | |
3 | Right heated hand grip cap | 56100337 | |
Kit 56100342 | 1 | Left heated hand grip | 56100316 |
2 | Right heated hand grip | 56100317 | |
3 | Right heated hand grip cap | 56100168 | |
Kit 56100436, Chrome | 1 | Left heated hand grip | 56100430 |
2 | Right heated hand grip | 56100433 | |
3 | Right heated hand grip cap | 56100472 | |
Kit 56100437, Black | 1 | Left heated hand grip | 56100431 |
2 | Right heated hand grip | 56100434 | |
3 | Right heated hand grip cap | 56100471 | |
Kit 56100438, Edge cut | 1 | Left heated hand grip | 56100432 |
2 | Right heated hand grip | 56100435 | |
3 | Right heated hand grip cap | 56100470 | |
Items common to ALL Kits | 4 | Adapter harness | 69200232 |
5 | Splice connector (2) | 70586-93 | |
6 | Interconnect jumper (black/white, 14 in) | 69201809 | |
7 | Power/Ground jumper (red/black, 20 in) | 69201808 |