BLACK HAND CONTROLS FOR DYNA AND SOFTAIL MODELS
J041552006-08-25
GENERAL
Kit Number
70239-07 (BLACK)
Models
This kit is designed for installation on 96 and later Sportster®, Dyna™, Softail®, and Road King® models except Road King Classic or 2007 and later FLSTF.
Does not fit vehicles equipped with cruise control.
2006 and later FXDWG and FXDB require separate purchase of Directional relocation kit: 68564-06.
Additional Parts Required
Tools:
- Deutsch terminal crimp tool part HD-42879
- Molex terminal crimp tool part HD-48119
- Molex terminal removal tool part HD-48114
WARNINGRider 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 your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
INSTALLATION
| 1. | Disconnect battery, remove seat and fuel tank following instructions in applicable Service Manual. | |
| WARNING To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) WARNINGDisconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) | ||
| 2. | Review the Right and Left Handlebar Switch section of the applicable Softail or Dyna Service Manual before attempting to install this kit. NOTE Both Right and Left hand control assemblies will come with terminated ends. The terminal ends provided will not be used, instead the harness is to be cut to length, and new terminals will be installed. |
Install New Right Handlebar Control with Harness
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)
- Remove the right side hand control from vehicle.
Refer to Right Hand Control section of applicable Service Manual for detailed instructions.
- Trace the right handlebar wiring harness to the 6-pin connector and disconnect connector halves.
- See Figure 2. Select the new Right Handlebar Control and Harness Assembly (2) from the kits.
- The new harness has Molex pin connectors in place. The harness may need to be modified for your motorcycle. After removing the existing Harness, measure it to verify its length, and compare it with the length in Table 2.
- See Service Manual for crimping and assembly instructions of terminals and electrical connectors. 1996 through 2006 vehicles use Deutsch connectors. 2007 and later vehicles use Molex connectors. Right side connectors will be black in color.
- See Table 1 to determine pin-out cavity assignments based on wire colors of hand control harness.
NOTE
Note the existing harness routing and cable ties securing the harness to handlebars.
NOTE
If alternate handlebars and/or risers are used, it will be necessary to fully route the harness to verify the new custom length. Cut harness to appropriate length only after accounting for slack in full range of steering motion.
NOTE
For motorcycles with internally wired handlebars: route the harness through the handlebars before adding Molex or Deutsch connector.
Table 1. Pin-out Assignments
RH or LH | Connector Type | Cavity Number | Wire Color |
|---|---|---|---|
RH | Deustch 6-Pin (Black) 1996 through 2006 | 1 | O/W |
2 | R/Y | ||
3 | GY | ||
4 | W/BK | ||
5 | W/BN | ||
6 | BK/R | ||
LH | Deustch 6-Pin (Gray) 1996 through 2006 | 1 | O/W |
2 | Y | ||
3 | BE | ||
4 | W | ||
5 | W/V | ||
6 | Y/BK | ||
RH | Molex 6-Pin (Black) 2007 and Later | 1 | O/W |
2 | R/Y | ||
3 | GY | ||
4 | W/BK | ||
5 | W/BN | ||
6 | BK/R | ||
LH | Molex 8-Pin (Gray) 2007 and Later | 1 | O/W |
2 | Y | ||
3 | BE | ||
4 | W | ||
5 | W/Y | ||
6 | Y/BK | ||
7 | *BK/R | ||
8 | *BK | ||
* See Page 4, Wires Not Used | |||
Table 2. Harness Wire Length
Family | Model | Year | Wire Length Left inches (cm) | Wire Lenght Right inches (cm) |
|---|---|---|---|---|
DYNA | All DYNA | 1996 through 2005 | 35.75 (90.8) | 42.5 (108.0) |
FXD, FXDL, FXDC, FXD35 | 2006 | 29.5 (74.9) | 30.0 (76.2) | |
FXDWG, FXDB | 2006 through 2007 | 39.75 (101.0) | 39.75 (101.0) | |
FXD, FXDL, FXDC, FXD35 | 2007 | 30.0 (76.2) | 30.5 (77.5) | |
TOURING | FLHR | 1996 through 2006 | 21.25 (54.0) | 21.25 (54.0) |
FLHRS | 2004 through 2006 | 23.0 (58.4) | 23.0 (58.4) | |
FLHR | 2007 | 21.75 (55.2) | 21.75 (55.2) | |
FLHRS | 2007 | 24.75 (62.9) | 24.75 (62.9) | |
SOFTAIL | ALL EXCEPT FXSTB, FXSTD, or 2004 THROUGH 2006 FXSTS | 1996 through 2006 | 37.25 (94.6) | 34.25 (87.0) |
FXSTB, FXSTD | 1996 through 2003 | 33.75 (85.7) | 32.25 (81.9) | |
FXSTB, FXSTD | 2004 through 2006 | 28.25 (71.8) | 32.25 (81.9) | |
FXSTS | 2004 through 2006 | 28.75 (73.0) | 28.25 (71.8) | |
ALL EXCEPT FXSTB or FXSTD | 2007 | 34.25 (87.0) | 34.75 (88.3) | |
FXSTB | 2007 | 28.75 (73.0) | 32.75 (83.2) | |
FXSTD | 2007 | 34.25 (87.0) | 32.75 (83.2) | |
XL | ALL EXCEPT CUSTOM | 1996 through 2003 | 28.25 (71.8) | 28.25 (71.8) |
XL883C, 1200C | 1996 through 2003 | 21.25 (54.0) | 21.25 (54.0) | |
XL883C, 1200C, XL883L, 1200L, XL883R, 1200R | 2004 through 2007 | 32.25 (81.9) | 32.25 (81.9) | |
XL883 | 2004 through 2007 | 28.75 (73.0) | 28.75 (73.0) | |
| 1 | Molex |
| 2 | Deustch |
Figure 1. Hand Control Connectors
- Install new connector in same location as stock connector was removed in Step 1.
- Adjust the harness so it runs under the lower handlebar and then using two harness retainers from the kit, secure the harness conduit to lower side of handlebar by inserting barbed ends of retainers into holes in lower side of handlebar.
Install New Left Handlebar Control with Harness
- Remove the left side hand control from vehicle.
Refer to Left Hand Control section of applicable Service Manual for detailed instructions.
- Trace the left handlebar wiring harness to the 6-pin or 8-pin connector and disconnect connector halves.
- See Figure 2. Select the new Left Handlebar Control (1) and Harness Assembly from the kits.
- Compare the length of the hand control harness that was removed to the length of the control harness provided with the kit, and cut new harness to same length.
- See Table 1 to determine appropriate connector and terminals based on vehicle model and year.
- See Service Manual for crimping and assembly instructions of terminals and electrical connectors. 1996 through 2006 vehicles use Deutsch connectors. 2007 and later vehicles use Molex connectors. Left side connectors will be gray in color.
- See Table 1 to determine pin-out cavity assignments based on wire colors.
- Install new connector in same location as stock connector was removed in Step 1.
- See Table 3. Adjust the harness so it runs under the lower handlebar and then using two harness retainers (3) from the kit, secure the harness conduit to lower side of handlebar by inserting barbed ends of retainers into holes in lower side of handlebar.
NOTE
Note the existing harness routing and cable ties securing the harness to handlebars.
NOTE
If alternate handlebars and/or risers are used, it will be necessary to full route the harness to verify the new custom length. Cut harness to appropriate length only after accounting for slack in full range of steering motion.
NOTE
* Wires Not Used: 1996 through 2006 Left hand controls will only use 6 of the 8 wires contained in the hand control harness. Pull back the vinyl conduit and cut the 2 unused wires at the 6-way connector (BLACK and BLACK WITH RED STRIPE). These wires will not be used.
Connecting and Securing the Harness
- Connect the black connector of the right hand control to the mating gray connector of the main vehicle Harness.
- Connect the gray connector of the left hand control to the mating gray connector of the main vehicle Harness.
- Secure the hand control harness to the vehicle harness using cable straps from kit.
RETURN THE VEHICLE TO SERVICE
| 1. | Install the fuel tank. | |
| 2. | Reconnect the battery, positive (+) cable first. | |
| WARNING Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a) WARNINGBe sure headlamp, tail and stop lamp and turn signals are operating properly before riding. Poor visibility of rider to other motorists can result in death or serious injury. (00478b) WARNINGAfter 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) | ||
| 3. | Install seat. |
- Verify that the steering is not limited in any way by harness routing.
- Verify full range of motion for turning by checking steering in full right and left lock position.
- Verify Operation of all switches before operating vehicle.
SERVICE PARTS
Figure 2. Service Parts
Table 3. Service Parts Table
Item | Handlebar Control, Black, Kit 70239-07 (Quantity) | Part Number |
|---|---|---|
1 | Handlebar Control, Left Hand, Black | 70539-07 |
2 | Handlebar Control, Right Hand, Black | 70560-07 |
3 | Retainer, Wiring (4) (Not Shown) | 70345-84 |
4 | Housing, 6-way Socket, gray (Not Shown) | 72136-94GY |
5 | Housing, 6-way Socket, black (Not Shown) | 72116-94BK |
6 | Terminal, Socket, #16-20AWG (12) (Not Shown) | 72191-94 |
7 | Lock, Secondary, 6-way Socket (Not Shown) | 72156-94 |
8 | Seal, Front (2) (Not Shown) | 72176-94 |
9 | Housing, 8-way Pin, gray (Not Shown) | 72447-07GY |
10 | Housing, 6-way Pin, black (Not Shown) | 72188-07BK |
11 | Terminal, Pin, #16-20AWG (14) (Not Shown) | 72169-07 |
12 | Screw, #10-24 x 1/2 Hex Socket, Button Head (4) (Not Shown) | 3658 |