w w w. h d o n l i n e s h o p. d e HEATED HAND GRIP KITS GENERAL REMOVAL -J02983 REV Kit Number Models Kit numbers Service Parts

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1 -J098 REV GENERAL Kit Number B, B, B, B, 565-0B, A, A, A, A, , , Models For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of (English only). Each kit contains one pair of heated hand grips of the style shown in the chart below, plus the connecting parts. See Figure 0 and Table for a list of kit contents. Kit numbers Kit Number B B B B 565-0B A A A A Table. Models Flame HEATED HAND GRIP KITS Hand Grip Style Smooth-Grain Leather Chrome and Rubber Large Diameter.66 inch (4 mm) diameter Chrome and Rubber Small Diameter.5 inch (8 mm) diameter Contoured Chrome and Rubber Custom Nostalgic Heated Diamond Plate Heated Aileron Heated Stealth Heated H.O.G. Collection Skull Collection Ironside It is possible to overload your motorcycle's charging system by adding too many electrical accessories. If your combined electrical accessories operating at any one time consume more electrical current than your vehicle's charging system can produce, the electrical consumption can discharge the battery and cause vehicle electrical system damage. See a Harley-Davidson dealer for advice about the amount of current consumed by additional electrical accessories, or for necessary wiring changes. (00b) These kits requires up to.8 amps additional current from the electrical system. When installing any electrical accessory, be certain not to exceed the maximum amperage rating of the fuse or circuit breaker protecting the affected circuit being modified. Exceeding the maximum amperage can lead to electrical failures, which could result in death or serious injury. (000a) The rider's safety depends 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. (00a) 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. Service Parts See Figure 0 and Table. REMOVAL Stock Hand Grip To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a). Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (-) battery cable. Retain all seat mounting hardware.. For VRSC models only: Remove the air box aluminum cover according to Service Manual instructions. For all other models: Remove the fuel tank according to Service Manual instructions.. Refer to the RIGHT HANDLEBAR SWITCH section of the Service Manual to remove the switch housing assembly. This is necessary to access the throttle cables. 4. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables and remove the -J098 of

2 existing right grip/throttle sleeve assembly. After removal, make sure that the handlebar end is clean and smooth. 5. Using a T-7 TORX drive head, remove the two screws with flat washers securing the handlebar clamp to the clutch lever bracket. Remove the clamp and position the clutch hand lever assembly away from the handlebar. 6. Using a T-5 TORX drive head, loosen but do not remove the upper and lower switch housing screws. 7. Remove the end cap from the existing left handlebar grip if so equipped. Remove the grip. If grip is the glued-on type, carefully cut it away from the handlebar using a sharp blade or knife. 8. Refer to the Service Manual and remove the handlebar cover, riser cover or outer fairing if equipped. INSTALLATION Heated Hand Grip. See Figure 0 and Table. Determine if the wire harness extension (7) is required for this installation: Hold the right heated hand grip throttle and wire harness in position along the outside of the handlebar as if the assembly were installed on the handlebar. The connector at the end of the wire harness on the heated hand grip throttle must extend past the left end of the handlebar. If the connector extends past the opposite end of the handlebar, the extension will not be needed and can be discarded. If the connector does not extend past the opposite end of the handlebar, connect the extension to the connector at the end of the right heated hand grip wire harness.. Lightly apply soapy water to the outside of the vinyl jacket on the wire harness (and extension, if installed) connected to the right heated hand grip throttle.. Thread the connector and wire from the heated hand grip throttle into the right side of the handlebar, all the way through and out the left side of the handlebar. Use air pressure or an electrician's fish tape to thread the connector and wire completely through the handlebar. 4. Install the heated hand grip throttle, throttle cables and switch housing onto the right handlebar according to the stock throttle installation procedures in the Service 5. Fasten the connector on the left side of the handlebar to the left-hand heated hand grip (). 6. Use a strip of masking tape or a grease pencil to mark the left handlebar 4-/4 in (0 mm) from the left end of the handlebar. 7. Use a blunt, flexible object (such as a narrow rubber hose) in one hand to gently feed the wiring from the left hand grip into the handlebar, while using your other hand to ease the hand grip into position near the end of the handlebar. Do not lubricate left handlebar grip before installation. Lubricating grip can cause it to come off while riding, which could result in loss of control and death or serious injury. (005a) Make sure that the handlebar surface and the inside of the grip are smooth, dry and thoroughly cleaned of all dirt or adhesive residue. 8. Remove the flexible object from inside the handlebar and carefully slide the left hand grip onto the handlebar, taking care not to crush, pinch or otherwise damage the wiring inside the handlebar. Push the hand grip onto the handlebar up to the marking from Step See Figure. Position the left heated hand grip on the handlebar so the hand grip retaining flange () can be securely installed into the lower switch housing (). is000. Retaining flange. Route hand grip main harness outside and under the switch housing Figure. Heated Hand Grip (Left Side) Do not route the handgrip main harness inside the switch housing. Wires routed inside the switch housing could result in short circuits and equipment damage. (0069a) 0. Route the heated hand grip main wire harness between the hand grip and left switch housing, then under the switch housing ().. See Figure 0. If equipped with holes on the left underside of the handlebar, install wire retainer clips () from the kit in the holes and then fasten the wire harness to the clips. -J098 of

3 Otherwise, use cable straps (8) to fasten the wire harness to the handlebar. is00. Fasten the switch housing to the hand grip and handlebar according to the Service Manual instructions.. Follow the existing wiring to route the heated hand grip main wire harness: through, across or around the triple tree, along the motorcycle frame, to a general location under the seat For VRSC models only: Route the red wire near the battery positive terminal, located toward the front right side of the frame. 4. See Figure 0. Use cable straps (8) from the kit to fasten the hand grip wiring to the wire harnesses along the vehicle frame. 5. Proceed to the following section covering your model motorcycle.. Screw. Ignition switch Figure. Ground Connection (VRSC Models) is0458. Accessory fuse (orange/white wire). Fuse box Figure. Fuse Box (VRSC Models) VRSC (V-Rod) Models. See Figure. At the accessories fuse () in the fuse box (), cut the orange/white wire. Cut to allow enough wire to easily strip and splice the wires.. Cut the orange/white wire from the heated hand grip harness to within easy reach of the wires cut in Step.. See Figure 0. Use a butt splice connector () from the kit to splice together the three orange/white wires, from Steps and, according to Appendix B in the Service 4. See Figure. Remove the screw () (located under the seat) that fastens the ignition switch () to the right side of the frame. 5. Scrape the paint from the top of the frame where the screw () in Step 4 was removed, to ensure a strong ground contact. 6. Select a ring terminal from the kit that fits the screw removed in Step 4. Crimp the ring terminal onto the heated hand grip ground wire according to Appendix B in the Service 7. Install the ground wire ring terminal onto the threads of the screw from Step 4. Install the screw to the ignition switch and tighten to 5-88 in-lbs (6-0 Nm). 8. Select a ring terminal from the kit that fits the positive terminal fastener on the battery. 9. Cut the red wire to length without removing the built-in fuse. 0. Crimp the ring terminal onto the end of the red wire according to Appendix B in the Service. Fasten the red wire ring terminal to the positive terminal mounting post on the battery. Tighten the terminal fastener to in-lbs (7-0 Nm).. Proceed to the All Models Section. 00 or Earlier XL (Sportster) Models. Remove the electrical side cover, located on the left side of the motorcycle near the battery.. Route the heated hand grip wire harness through the top of the frame under the seat to the circuit breaker located on the inside of the electrical side cover.. See Figure 4. Remove the ground screw (), located: under the seat on some models, or near the swingarm on 995 or earlier models, and models without a screw under the seat. 4. Cut the heated hand grip ground wire (black) to within easy reach of the ground screw removed in Step. -J098 of

4 is00 The power wire (red) from the heated-handgrip wire harness must connect to the circuit-breaker silver terminal. Connecting to the circuit-breaker copper terminal can cause circuit overload, which could result in equipment damage. (0070a) 7. Cut the red wire to length without removing the built-in fuse. 8. Crimp the ring terminal onto the end of the red wire according to the instructions in Appendix B in the Service 9. Fasten the red wire ring terminal to the circuit breaker silver terminal. Tighten the terminal nut to 0-5 in-lbs (.-4.0 Nm). 0. See Figure 6. Cut the orange/white wire () in the stock wire harness inside the electrical side cover or under the seat. Cut to allow enough wire to easily strip and splice the wires.. Ground screws (black wire) Figure 4. Ground Connections (00 or Earlier XL Models) is004. Circuit-breaker, silver terminal (red wire) Figure 5. Circuit Breaker (00 or Earlier XL Models) 5. Select a ring terminal from the kit that fits the screw removed in Step. Crimp the ring terminal onto the heated hand grip ground wire according to the instructions in Appendix B in the Service 6. See Figure 5 and Figure 6. Select a ring terminal from the kit that fits the silver terminal () on the circuit breaker (located inside the electrical side cover). is006. Left side cover containing circuit breaker silver terminal (red wire). Stock wire harness (orange/white wire) Figure 6. Power Connections (XL Models). See Figure 0. Use a butt splice connector () from the kit to splice the orange/white wire from the heated hand grips to the orange/white wires from the stock wire harness, according to Appendix B section in the Service. Proceed to the All Models Section. 004 or Later XL (Sportster) Models. Remove the electrical side cover, located on the left side of the motorcycle near the battery.. Route the heated hand grip wire harness through the top of the frame under the seat to the circuit breaker located on the inside of the electrical side cover.. Remove the ground screw, located on the engine near the starter. 4. Cut the heated hand grip ground wire (black) to within easy reach of the ground screw removed in Step. -J098 4 of

5 is007 is008 A. B+ connector. Cover Figure 7. B+ Connector B 5. Select a ring terminal from the kit that fits the screw removed in Step. Crimp the ring terminal onto the heated hand grip ground wire according to Appendix B in the Service Insert the ground screw through the ring terminal, and reestablish the ground connection. 6. See Figure 7. Locate the B+ (battery positive) connector () (a red wire with an unused gray connector) on the main electrical harness, routed under the seat, beneath the ECM (Electronic Control Module). Remove the cover () from the connector. 7. See Figure 0. Plug the adapter harness (0) into the B+ connector. 8. Cut the heated hand grip harness red wire to within easy reach of the end of the adapter harness red wire. Splice the two wires using a butt splice connector (see Figure 0, item ) from the kit following the instructions in Appendix B section in the Service 9. See Figure 6. Cut the orange/white wire () in the stock wire harness inside the electrical side cover or under the seat. Cut to allow enough wire to easily strip and splice the wires. 0. See Figure 0. Use a butt splice connector () from the kit to splice the orange/white wire from the heated hand grips to the orange/white wires from the stock wire harness, according to Appendix B section in the Service. Proceed to the All Models Section. 00 or Earlier Softail Models. Remove the ground screw, located on the top of the frame, under the seat near the fuel tank.. Cut the heated hand grip ground wire (black) to within easy reach of the ground screw removed in the previous section, "004 or Later Softail Models", Step.. Select a ring terminal from the kit that fits the ground screw. Crimp the ring terminal onto the heated hand grip ground wire according to Appendix B in the Service. Tail lamp harness (orange/white wire). Ground terminal (black wire). Battery 4. Item A, FXSTD Models 5. Item B, Softail Models except FXSTD Figure 8. Power Connections (00 or Earlier Softail Models) 4. See Figure 8. Place the ground-wire ring terminal onto the threads of the ground screw. Re-fasten the ground screw to the frame () and tighten securely. is009. Rear splash guard. Fuse box Figure 9. Splash Guard, 00 or Earlier Softail Models (00 Model Shown) 5. See Figure 9. Remove the rear fender splash guard () according to the instructions in the Service 6. See Figure 0. Route the heated hand grip red wire through the right-side top of the frame, under the seat, and to the circuit breaker located near the front of the rear fender splash guard and below the seat. 7. Select a ring terminal from the kit that fits the silver terminal on the circuit breaker. -J098 5 of

6 The power wire (red) from the heated-handgrip wire harness must connect to the circuit-breaker silver terminal. Connecting to the circuit-breaker copper terminal can cause circuit overload, which could result in equipment damage. (0070a) 8. Cut the red wire to length without removing the built-in fuse. 9. Crimp the ring terminal onto the end of the red wire according to the instructions in Appendix B in the Service 0. Fasten the red wire ring terminal to the circuit breaker silver terminal stud. Tighten the terminal nut to 0-5 inlbs (.-4.0 Nm).. See Figure 8. Cut the orange/white wire in the stock tail lamp wire harness () under the seat. Cut the wire allowing enough wire to easily strip and splice the wires.. Use the butt splice connector () from the kit to splice the orange/white wire from the heated hand grips to the orange/white wires from the stock wire harness, according to Appendix B section in the Service. Proceed to the All Models Section. is00. Fuse box. Circuit breaker silver terminal (red wire) Figure 0. Circuit Breaker (00 or Earlier FXSTD) 004 or Later Softail Models. Remove the ground screw, located on the top of the frame, under the seat near the fuel tank.. Cut the heated hand grip ground wire (black) to within easy reach of the ground screw removed in Step.. See Figure 8. Select a ring terminal from the kit that fits the screw removed in Step 6. Crimp the ring terminal onto the heated hand grip ground wire () according to the instructions in Appendix B in the Service 4. Install the ground wire ring terminal onto the threads of the screw from Step. Install the screw to the frame and tighten securely. 5. See Figure 7. Locate the B+ (battery positive) connector () on the main electrical harness under the seat (a red wire with an unused gray connector). Remove the cover () from the connector. 6. See Figure 0. Plug the adapter harness (0) from the kit into the B+ connector. 7. Cut the heated hand grip harness red wire to within easy reach of the end of the adapter harness red wire. Splice the two wires using a butt splice connector () from the kit following the instructions in Appendix B section in the Service 8. Remove the fuse block cover. Remove the two hex head screws fastening the fuse block bracket, and pull the bracket and fuse block assembly away from the motorcycle frame. 9. Depress the tab retaining the left fuse block, and slide the block out of the mounting slots. 0. See Figure 0. Obtain the orange/white fuse block adapter harness (9) from the kit. Note the terminal on each end (see Figure ). Only the terminal with the spring tabs will fit into this fuse block. Carefully cut the unused terminal from the wire and discard it. is0. Do NOT remove this terminal from wire. Cut this terminal from wire. Spring tabs Figure. Jumper Wire Terminals. Locate the fuse cavity indicated as "P&A IGN" on the fuse block cover (see Figure ). There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Insert the terminal on the orange/white adapter harness until it stops. Refer to a nearby factory installed terminal for comparison to ensure proper orientation and depth.. Cut the excess length from the heated hand grip harness orange/white wire to within easy reach of the adapter wire installed in Step. Using a butt splice connector () from the kit, splice the orange/white wire to the adapter wire following the instructions in Appendix B in the Service -J098 6 of

7 is04587 is04 STARTER BRAKE RELAY P&A IGN AMP MAX BATTERY 5 AMP RADIO PWR 0 AMP (SIREN) RADIO MEM. 5 AMP RELAY (ROAD KING) P&A ACCESSORIES CRUISE/BRAKE 5 AMP 5 AMP 5 AMP (PURSUIT) HEADLAMPS IGN LIGHTS INSTRUMENTS 5 AMP 5 AMP 5 AMP 5 AMP (POLICE CONTENT IN PARENTHESIS). P&A IGN, A MAX fuse location Figure. "P&A IGN" Fuse Cavity (004 and Later Touring Models). See Figure 0. Install the A fuse () from the kit into the "P&A IGN" fuse cavity to complete the circuit. 4. Slide the fuse block into the mounting slots in the fuse block bracket until it clicks firmly into place. Install the bracket and fuse block assembly into position and fasten with the two hex head screws removed earlier. Tighten securely. 5. Proceed to the All Models Section. 00 or Earlier Dyna Models. Remove the nut from the ground screw, located on the top of the frame, under the seat near the fuel tank.. See Figure. Cut the heated hand grip ground wire (black) to within easy reach of the ground screw. is0. Tail lamp harness (orange/white wire). Ground terminal (black wire) Figure. Heated Hand Grip Power and Ground Connections (Dyna Models). Select a ring terminal from the kit that fits the ground screw. Crimp the ring terminal onto the heated hand grip ground wire according to the instructions in Appendix B in the Service 4. Place the ground-wire ring terminal onto the threads of the ground screw. Re-fasten the nut to the ground screw and tighten securely.. Circuit breaker silver terminal (red wire) Figure 4. FXDXT Connections, Bottom View with Left Side Cover Removed 5. Remove the electrical side cover, located on the left side of the motorcycle near the battery. 6. See Figure 4. Route the heated hand grip wire harness through the top of the frame under the seat to the circuit breaker () located on the inside of the electrical side cover. 7. Select a ring terminal from the kit that fits the silver terminal stud on the circuit breaker (located inside the electrical side cover). The power wire (red) from the heated-handgrip wire harness must connect to the circuit-breaker silver terminal. Connecting to the circuit-breaker copper terminal can cause circuit overload, which could result in equipment damage. (0070a) 8. Cut the red wire to length without removing the built-in fuse. 9. Crimp the ring terminal onto the end of the red wire according to the instructions in Appendix B in the Service 0. Fasten the red wire ring terminal to the circuit breaker silver terminal stud. Tighten the terminal nut to 0-5 inlbs (.-4.0 Nm).. See Figure. Cut the orange/white wire in the stock wire harness inside the electrical side cover. Cut to allow enough wire to easily strip and splice the wires.. Use the butt splice connector () from the kit to splice the orange/white wire from the heated hand grips to the orange/white wires from the stock wire harness, according to Appendix B in the Service. Proceed to the All Models Section. 004 or Later Dyna Models. Remove the nut from the ground screw, located on the top of the frame, under the seat near the fuel tank. -J098 7 of

8 . See Figure. Cut the heated hand grip ground wire (black) to within easy reach of the ground screw. 00 or Earlier Touring Models. Select a ring terminal from the kit that fits the ground screw. Crimp the ring terminal onto the heated hand grip ground wire according to Appendix B in the Service 4. Install the ground wire ring terminal onto the threads of the ground screw. Re-fasten the nut to the ground screw and tighten securely. 5. Remove the electrical side cover, located on the left side of the motorcycle near the battery, by firmly grasping both sides and pulling outward. 6. See Figure 4. Route the heated hand grip wire harness through the top of the frame under the seat to the circuit breaker () located on the inside of the electrical side cover. 7. See Figure 7. Locate the B+ (battery positive) connector () on the main electrical harness under the seat (a red wire with an unused gray connector). Remove the cover () from the connector. 8. See Figure 0. Plug the adapter harness (0) from the kit into the B+ connector. 9. Cut the heated hand grip harness red wire to within easy reach of the end of the adapter harness red wire. Splice the two wires using a butt splice connector () from the kit following the instructions in Appendix B in the Service 0. Remove the electrical panel from the vehicle according to the instructions in the Service. Note the terminal on each end of the orange/white fuse block adapter harness (9) (see Figure ). Only the terminal with the spring tabs will fit into this fuse block. Carefully cut the unused terminal from the wire and discard it.. See Figure. Locate the fuse cavity (4) indicated as "OPEN" on the fuse block cover in the right fuse block. There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Insert the terminal on the orange/white adapter harness until it stops. Refer to a nearby factory installed terminal for comparison to ensure proper orientation and depth.. Cut the excess length from the heated hand grip harness orange/white wire to within easy reach of the adapter wire installed in Step. Using a butt splice connector () from the kit, splice the orange/white wire to the adapter wire following the instructions in Appendix B in the Service 4. See Figure 0. Install the A fuse () from the kit into the "OPEN" fuse cavity to complete the circuit. 5. Re-install the electrical panel according to the instructions in the Service Install the electrical panel cover by aligning the pins with the rubber bushings in the electrical panel and pushing firmly into place. 6. Proceed to the All Models Section. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (0007a) Disconnect 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). Ensure the negative battery was disconnected in Step. If not, disconnect it following the instructions in the Service Then refer to the Service Manual and follow the instructions given to disconnect the positive battery cable.. Remove the battery from the motorcycle.. See Figure 5. Route the heated hand grip red wire to the silver terminal stud of the circuit breaker (), located in the battery well under the seat. 4. Select a ring terminal from the kit that fits the silver stud on the circuit breaker. is05. Circuit breaker silver terminal (red wire). Ground terminal (black wire) Figure 5. Connections (with battery removed) - 00 or Earlier Touring Models (00 FLHTCU shown) The power wire (red) from the heated-handgrip wire harness must connect to the circuit-breaker silver terminal. Connecting to the circuit-breaker copper terminal can cause circuit overload, which could result in equipment damage. (0070a) 5. Cut the red wire to length without removing the built-in fuse. The red wire should remain long enough so the battery fits into the well without stressing or stretching the wire. 6. Crimp the ring terminal onto the end of the red wire according to Appendix B in the Service -J098 8 of

9 7. Fasten the red wire ring terminal to the circuit breaker silver terminal stud. Tighten the terminal nut to 0-5 inlbs (.-4.0 Nm). 8. Route the heated hand grip ground wire (black) to the ground stud () located below the circuit breaker in the battery well under the seat. 9. Cut the black wire to within easy reach of the ground stud. The black wire should remain long enough so the battery fits into the well without stressing or stretching the wire. 0. Select a ring terminal from the kit that fits the ground stud. Crimp the ring terminal onto the heated hand grip ground wire according to Appendix B in the Service. Connect the ring terminal to the ground stud. is06. Fuse box harness (orange/white wire) Figure 6. Fuse Box Harness Behind Left-Hand Side Cover, 00 or Earlier Touring Models (FLHTCUI Shown). See Figure 6. Cut the orange/white wire () in the stock wire harness inside the electrical side cover. Cut to allow enough wire to easily strip and splice the wires.. See Figure 0. Use a butt splice connector () from the kit to splice the orange/white wire from the heated hand grips to the orange/white wires from the stock wire harness following the instructions in Appendix B in the Service 4. Install the battery back into the vehicle. 5. Proceed to the All Models Section. 004 or Later Touring Models. See Figure 7. Locate the B+ (battery positive) connector () on the main electrical harness under the seat (a red wire with an unused gray connector). Remove the cover () from the connector.. See Figure 0. Plug the adapter harness (0) from the kit into the B+ connector.. Cut the heated hand grip harness red wire to within easy reach of the end of the adapter harness red wire. Splice the two wires using a butt splice connector () from the kit following the instructions in Appendix B in the Service 4. For Models: Remove the left side cover per the instructions in the Service Manual to access the fuse box. For 007 Models: Remove the right side cover per the instructions in the Service Manual to access the fuse box. All Models: Remove maxi-fuse holder, fuse block and dust cover from the vehicle per the instructions in the Service 5. For Models: Note the terminal on each end (see Figure 7). Only the terminal WITHOUT the spring tabs will fit into the fuse cavity. Carefully cut the terminal WITH the spring tabs from the wire and discard. For 007 Models: Note the terminal on each end (see Figure 7). Only the terminal WITH the spring tabs will fit into the fuse cavity. Carefully cut the terminal WITHOUT spring tabs from the wire and discard. 6. See Figure 8. Locate the fuse cavity marked "P&A IGN", "A MAX" (4). There should be a wire feeding one side of this circuit, but no mating wire or fuse will be present. Remove the three existing fuses in this row. 7. Gently remove the orange plastic secondary lock from the fuse block. Insert the terminal on the orange/white adapter harness until it stops. Refer to a nearby factory installed terminal for comparison to ensure proper orientation and depth. is07. Do NOT remove this terminal from wire. CUT this terminal from wire. Spring tabs is04587 Figure 7. Jumper Wire Terminals STARTER RELAY (ROAD KING) BRAKE RELAY P&A 5 AMP P&A IGN AMP MAX BATTERY 5 AMP ACCESSORIES 5 AMP RADIO PWR 0 AMP (SIREN) RADIO MEM. 5 AMP CRUISE/BRAKE 5 AMP (PURSUIT) HEADLAMPS IGN LIGHTS INSTRUMENTS 5 AMP 5 AMP 5 AMP 5 AMP (POLICE CONTENT IN PARENTHESIS). P&A IGN, A MAX fuse location Figure 8. "P&A IGN" Fuse Cavity (004 and Later Touring Models) 8. Reinstall the secondary lock and the three fuses removed in Step 6. -J098 9 of

10 9. See Figure 0. Cut the excess length from the orange/white heated hand grip harness wire. Using a butt splice connector () from the kit, splice that wire to the adapter wire installed in Step Install the A fuse () from the kit into the fuse cavity marked "P&A IGN", "A MAX" to complete the circuit.. Proceed to All Models Section. All Models DO NOT perform the following steps until the heated hand grips and all related wiring have been installed according to the procedures outlined in this instruction sheet for your model motorcycle.. Verify that the right grip/throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing. DO NOT operate the vehicle unless the throttle functions properly. 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). Connect the battery cables, positive cable first.. VRSCA models only: Install the air box aluminum cover according to Service Manual instructions. All other models: Install the fuel tank according to Service Manual instructions. 4. Install the handlebar cover, riser cover or outer fairing, if equipped, according to Service Manual instructions. 5. Install the seat according to the instructions in the Service 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) To prevent battery drain, these heated hand grips are designed to function only with the engine running. The hand grips produce peak heat with the engine running at cruising speed. The heat settings on the heated hand grip control dial range from (minimum) to 6 (peak). 6. Before starting the vehicle, check that the hand grips are not producing heat. 7. Start the engine and check the hand grips at all settings for proper heating. TROUBLESHOOTING See Figure 9 for the heated hand grip schematic diagram. Hand Grips Do Not Produce Heat. See Figure. Check for proper wire routing. The hand grip main harness must be routed outside of the switch housing. If the wires were routed internally, disassemble the left hand switch housing and inspect for pinched wires. If wires are pinched, replace the left hand grip and repeat the installation process with the correct wire routing.. Check the wire connections of the orange/white, red and black hand grip main wire harness wires. If a connection is broken or weak, repair the connection and test the hand grips. Otherwise, go to Step.. Open or remove the seat according to Service Manual instructions. 4. Start the motorcycle. 5. Check for Vdc across the red and black wires of the hand grip main wire harness. If Vdc is not present across the wires, check the fuse in the wire harness and replace it if blown. Otherwise, replace the left grip and wire harness and test the hand grips. 6. Remove the right hand grip from the handlebar. 7. Disconnect the connector on the right hand grip from the left hand grip wire harness. 8. Check continuity across the two connector leads in the right hand grip. If the test shows continuity, the hand grips are functional. Hand Grips Produce Heat with Ignition (Key) Switch Off If the hand grips produce heat with the ignition switch off, then either the hand grips are incorrectly wired to the vehicle, or the left side grip and wire harness are faulty. Carefully check all heated hand grip wire connections on the vehicle. If the connections are correct, replace the heated hand grip main wire harness, then test the hand grips. -J098 0 of

11 is Left hand grip. Heat control. Positive to main circuit breaker or battery + connector 4. Fuse 5. Positive to accessory power 6. Negative ground 7. Right hand grip SERVICE PARTS is00 Figure 9. Heated Hand Grip Schematic Figure 0. Service Parts: Heated Hand Grip Kits -J098 of

12 Table. Service Parts Table Item Description (Quantity) Items - are common to all kits Butt splice connector () Ring terminal, #0 () Ring terminal, /4 inch () Ring terminal, 5/6 inch Wire harness extension, 0.5 inch (6.7 cm) long Cable strap, black, 7.75 inch long (8) Part Number Item 9 0 Description (Quantity) Items - are common to all kits Wire harness, fuse block adapter Wire harness, adapter Wire retainer clip (4) Fuse, mini-type, amp Fuse, in-line, 5 amp (fuse holder shown) Part Number See the list below for the hand grip numbers for items and in each kit. Flame Heated Hand Grip Kit Diamond Plate Heated Hand Grip Kit Kit Number B: Kit Number A: Heated hand grip, left A Heated hand grip, left Heated hand grip, right Heated hand grip, right Smooth-Grain Leather Heated Hand Grip Kit Kit Number: B: Aileron Heated Hand Grip Kit Kit Number A: Heated hand grip, left A Heated hand grip, left Heated hand grip, right Heated hand grip, right Chrome and Rubber Large Diameter Heated Hand Grip Kit Stealth Heated Hand Grip Kit Kit Number B (.66 inch / 4 mm Diameter): Kit Number A: Heated hand grip, left Heated hand grip, right A Chrome and Rubber Small Diameter Heated Hand Grip Kit Heated hand grip, left Heated hand grip, right H.O.G. Collection Hand Grip Kit Kit Number B (.50 inch / 8 mm diameter): Kit Number : Heated hand grip, left Heated hand grip, right A Contoured Chrome and Rubber Heated Hand Grip Kit Kit Number 565-0B: Heated hand grip, left A Heated hand grip, right Heated hand grip, left Heated hand grip, right Skull Collection Hand Grip Kit Kit Number : Heated hand grip, left Heated hand grip, right A A A Nostalgic Heated Hand Grip Kit Ironside Heated Hand Grip Kit Kit Number A: Kit Number : Heated hand grip, left A Heated hand grip, left Heated hand grip, right Heated hand grip, right J098 of