HARLEY DAVIDSON HEATED HAND GRIP KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 08-02-2011

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REMOVAL Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the service manual and follow the instructions given to remove the main fuse. 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) 2. Remove the fuel tank according to the service manual instructions. -J04259 1 of 8 Left-Side Grip Removal 1. See Figure 1. Using a T-25 TORX drive head, remove the upper and lower switch housing screws (1). 2. Using a T-27 TORX drive head, loosen the upper screw securing the handlebar clamp (3) to the clutch lever bracket. Remove the lower clamp screw with flat washer. Loosen the clamp and position the clutch hand lever assembly away from the switch housing. Separate the upper and lower switch housings. 3. With “glueless” grip: Remove the grip from the handlebar. With glued grip: Remove the grip by carefully cutting it away from the handlebar using a sharp blade or knife. 2 2 1 5 4 3 1 is01283 1. Switch housing screws 2. Grooves 3. Handlebar clamp 4. Left handlebar grip 5. Larger diameter of flange Figure 1. Left Handlebar Switch Housing Right-Side Grip Removal 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) NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 2. 1. Place a 5/32-inch (4 mm) thick insert between the brake lever and the lever bracket. 2. Using a T-25 TORX® drive head, remove the upper and lower switch housing screws. 3. Using a T-27 TORX drive head, loosen the upper screw securing the handlebar clamp to the brake master cylinder housing. Remove the lower clamp screw with flat washer. Loosen the clamp and position the master cylinder assembly away from the switch housing. Separate the upper and lower switch housings. 4. Remove the grip from the handlebar. NOTES The twist grip sensor in the right side of the handlebar has a seal cap that protects internal electrodes from dirt and moisture, and also serves as a retention device for the throttle grip. To remove the grip, a slight tug may be necessary to release the index pins in the grip from the receptacle in the seal cap. Upon removing the grip, check the location of the seal cap. If the seal cap is still fastened to the index pins inside the old throttle grip, it can be discarded along with the grip. If the seal cap is still fastened to the end of the twist grip sensor: •See Figure 3. Insert a small screwdriver or other flat-blade tool into the flat area on one side of the seal cap. •Press the leg on the underside of the cap to free it from the slot at the end of the twist grip sensor. Pry up one end of the cap. •Repeat on the other side of the cap. •Carefully remove the cap and discard it

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HARLEY DAVIDSON HAND CONTROL LEVER KITS INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 02-02-2011

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INSTALLATION The rider’s safety depends upon the correct installation of this kit. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Dav- idson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00308a) Brake Lever Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) NOTE Do not remove handlebar clamp or switch housing assembly to remove brake lever. 1. See Figure 3. Remove the retaining ring (4) from the groove in the pivot pin (A). Do not position fingers between hand control lever and handlebar grip. Improper hand positioning can impair control lever operation and cause loss of vehicle control, which could result in death or serious injury. (00032a) 2. Place a 4 mm (5/32-inch) thick insert between the brake lever and the lever bracket. NOTE A section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose. See Figure 1. 3. See Figure 3. Loosen the brake master cylinder clamp screws. Rotate the master cylinder assembly slightly forward and then slide toward the center of the handlebar. 4. Remove the pivot pin (A) and original equipment (OE) brake lever. Retain the pivot pin for later assembly. 5. Apply a small amount of GM-40M grease (H-D Part No. 42820-04) to the area where the master cylinder pushrod seats against the brake lever. DO NOT apply grease to the stop-light switch contact surface of the lever. See Figure 2. Align the hole in the brake hand lever with the hole in the master cylinder bracket. From the top of the assembly, slide the pivot pin down through the bracket and hand lever. Check that the pushrod (1) is properly seated in the bowl shaped tab (2) on the lever

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