HANDLEBARS

941004152024-01-23

GENERAL INFORMATION

Table 1. General Information

Kits	Suggested Tools	Skill Level⁽¹⁾
55801469, 55801471, 55801473, 55801475, 55801477,55801479, 55801486, 55801491, 55801492, 55801493, 55801494, 55801499, 55801500, 55801501, 55801502	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

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.

Verify that the most current version of the instruction sheet is used. It is available at: h-d.com/isheets

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

Installation Requirements

Separate purchase of additional parts or accessories are required for proper installation of this handlebar kit. See a Harley-Davidson dealer, 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.

Separate purchase of handlebar mounted mirrors and fairing plugs are required for Street Glide models and models equipped with fairing mounted mirrors.

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)

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.

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.

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)

Loosen or remove fuel tank. See service manual.

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.

Cover nearby vehicle surfaces with a H-D Service Cover or polyethylene protective sheet to help protect against damage to the finish caused by spillage or splash of DOT 4 brake fluid.

2.	Remove inner and outer fairing assemblies. See service manual. a. Do not damage finished surfaces.
3.	Drain brake fluid from front brake reservoir and brake lines. See service manual.

REMOVE

Remove OE Handlebar.

NOTE

Cover painted parts to protect finish.
Remove windshield, if equipped.

NOTICE

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

2.	Note front brake line routing and orientation of the banjo fittings. a. Disconnect and remove brake line. See service manual. b. Save banjo bolts and discard sealing gaskets.
3.	Disconnect clutch cable from clutch lever. See service manual. a. Disconnect clutch cable from side cover. b. Remove cable from vehicle. NOTE Record wire routing and cable strap locations before removal.
4.	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. a. Disconnect handlebar wiring. See service manual. 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.
5.	Use tape to wrap connector ends from each individual harness to make separate leaders. a. Wrap each tight enough to enter the hole.
6.	Remove front brake master cylinder and clutch lever assemblies from handlebar. a. Remove attached turn signal lamps and mirrors, if needed.
7.	Remove wire harness from handlebar. a. Set handlebar control assemblies aside.
8.	Remove left side switch housing assembly and wire harness. See service manual.
9.	Remove hand grip and set it aside for installation to new handlebar, unless being replaced.
10.	Remove stock handlebar from handlebar risers. See service manual. a. Save hardware and riser parts for later installation.

New Handlebar Internal Wiring

NOTE

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

If required, extensions are applied to riser end of handlebar, not at hand controls.

1.	Stagger connectors so they are not in same locations along harness (2). 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.
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.

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)

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.	Repeat Steps 3 through 5 with left side switch wire bundle, and both turn signals, if needed.
6.	Remove tape from ends of wire bundles.
7.	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.
8.	If an 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

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 4. Install handlebar (1) to riser base. 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 bolts, but do not fully tighten. b. Models with Batwing Fairings: See Figure 5. Remove riser top clamp screw (1) prior to installing accessory handlbar.
3.	Adjust handlebar angle. a. Uprights of handlebar run roughly parallel to the front forks. NOTE Tighten front pair of riser screws first. Next tighten rear riser screws pair.
4.	With handlebar centered and oriented, secure riser clamp fasteners. Tighten. Torque: 21.7–24.2 N·m (16–18 ft-lbs)

Hand Control and Switch Wire Housing

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. a. Handlebars without weld: See Figure 4. Install clamp against dots on handlebar, keeping clamp slot between the two dots (2) or line (1). b. Handlebars with weld: See Figure 4. Install clamp against weld, keeping clamp slot between the two dots (2) or line (1). c. 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. Torque: 10–11 N·m (89–97 in-lbs)
4.	Tighten switch housing screws. Torque: 4–5.1 N·m (35–45 in-lbs)
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 sevice 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. Torque: 10–11 N·m (89–97 in-lbs)
9.	Torque switch housing screws. a. First secure lower switch housing screws. b. Then secure upper switch housing screws. c. Tighten. Torque: 4–5.1 N·m (35–45 in-lbs)
10.	Install proper length clutch cable (purchased separately). See service manual.

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.

Figure 4. Handlebar Markings

1	Riser Top Clamp Screw

Figure 5. Riser Top Clamp Screw

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 notes taken during removal.

COMPLETE

WARNING

Install fuel tank. 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 line 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.

Install main fuse. See service manual.

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 ignition switch to IGNITION, but do not start vehicle. a. Test all switches and lights for proper operation.
3.	Turn handlebar to the left and right steering stops, testing handlebar control functions at each stop.
4.	Apply front brake hand lever to test operation of brake lamp.

WARNING

After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)

Install seat. After installing seat, pull up on seat to verify that it is secure. See service manual.

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)