w w w. h d o n l i n e s h o p. d e STREET SLAMMER HANDLEBAR KIT GENERAL INSTALLATION -J03363 REV Kit Number Models Kit Contents

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1 -J06 REV GENERAL Kit Number 69-0 Models STREET SLAMMER HANDLEBAR KIT Ask a Harley-Davidson dealer or refer to the latest Harley- Davidson Genuine Motor Accessories and Genuine Motor Parts catalog to determine if this handlebar can be installed on your motorcycle. This kit does not fit models equipped with Heated Handgrips, Softail Nacelle Kit (Part Number ), Hydraulic Clutch Kits, handlebar mounted gauges or the Road Tech Radio. This kit is not to be used on FLHRS models equipped with an accessory windshield, as the handlebar-mounted turn signals will be obscured. The kit may be used with the original equipment chrome wind deflector. Additional Parts or Accessories Required Separate purchase of additional parts or accessories may be required for proper installation of this handlebar kit on your model motorcycle. Refer to the latest Harley-Davidson Genuine Motor Accessories and Genuine Motor Parts catalog for a list of required parts or accessories for your model. 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. (008a) For models that re-use the original brake line, the two brakeline gaskets found at each banjo fitting must be replaced. Refer to the appropriate Parts Catalog or see a Harley- Davidson dealer for the correct part numbers. Motorcycles equipped with a glued left-side hand grip will also require a new grip, sold separately. Refer to the Parts Catalog for replacement stock hand grips. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory hand grips that are available. 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. Kit Contents See Figure 8 and Table. INSTALLATION Preparation 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. (0009a). Refer to the Service Manual and follow the instructions to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. 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. (000a). For Dyna and Softail models: Remove the fuel tank. Refer to FUEL TANK REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. For FLHR, FLHRC and FLHRS models: Loosen the fuel tank. Refer to FUEL TANK-PARTIAL REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. 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) Direct contact of D.O.T. 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 D.O.T. brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00a) -J06 of 0

2 Direct contact of D.O.T. brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (000a). Proceed to "Original Handlebar Removal" for your model. Original Handlebar Removal, Dyna and Softail Cover the front fender with clean shop towels to prevent scratching. Damage to the finish could result. D.O.T. 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. (009b) If D.O.T. brake fluid contacts painted surfaces, flush IMMEDIATELY with clear water. On models with single front brake, only one length of plastic tubing is needed. On models with dual front brakes, connect a length of plastic tubing to each caliper. is0098. Caliper bleeder valve Figure. Draining Brake Fluid. See Figure. Open the bleeder nipple cap on each front brake caliper. Obtain a length of plastic tubing for each front brake. Install one end of a length of tubing over each caliper bleeder valve. Place the free ends of the tubing into a suitable container.. Open the bleeder valve about /-turn and pump the frontbrake hand lever to drain the fluid out of the front brake system. Do not re-use brake fluid. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (000a). Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake caliper and the front brake master cylinder assembly. Save the banjo bolts, but discard the two brake-line gaskets found at each banjo fitting. See FRONT BRAKE MASTER CYLINDER in the Service Manual.. Remove the old brake line from the motorcycle. For models with handlebar-mounted turn signals, remove the plastic wiring retainer clips that secure the turn signal harnesses to the handlebar.. Using a T7 TORX drive head, remove the front-brake master cylinder and clutch-lever assemblies from the handlebar.. Refer to CLUTCH HAND CONTROL: REMOVAL in the Service Manual, and follow the instructions to disconnect the clutch cable from the clutch lever and side cover. Remove and discard the cable. Molex connectors are used for the handlebar control wiring on 007 and later models. 006 and earlier vehicles use Deutsch connectors. Refer to the MOLEX ELECTRICAL CONNECTORS or DEUTSCH ELECTRICAL CONNECTORS section of the Service Manual for disconnection and re-connection procedures. Before disconnecting the handlebar control wiring, note the wire routing.. Disconnect the handlebar control wiring from the gray and black 6-way main harness connectors under the fuel tank. Before disconnecting the turn signal wiring, note turn signal wire routing. 6. For vehicles with handlebar-mounted turn signals, separate the 6-way turn signal connector halves. 7. Refer to HANDLEBAR SWITCHES; RIGHT HANDLEBAR CONTROLS section of the Service Manual for removal of the right-side switch housing assembly and harness. This is necessary to access the throttle cables. 8. Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables from the existing right grip/ throttle sleeve assembly. 9. Refer to the LEFT HANDLEBAR CONTROLS section of the Service Manual for removal of the left-side switch housing assembly and wire harness. -J06 of 0

3 0. See Figure. Remove and discard the screws () that fasten the handlebar upper clamps () to the risers (). Discard the clamps. Remove the handlebar () from the motorcycle.. If the left-side hand grip is not glued to the handlebar: Remove the hand grip and set it aside for installation to the new handlebar. FXSTD. Clamp screw (). Clamp ( on FXSTD, on others). Handlebar riser (). Handlebar. Riser attaching screw () is00 Figure. Handlebar Clamps and Risers (Dyna and Softail Models). Remove and discard the stock handlebar risers. Save the remaining hardware for later installation. S 007 and later models use Molex connectors. 006 and earlier vehicles use Deutsch connectors. Refer to MOLEX or DEUTSCH ELECTRICAL CONNECTORS in the Service Manual for terminal removal and re-installation procedures. DO NOT remove the wires from the Molex or Deutsch handlebar switch connector pin housings under the fuel tank. Models with handlebar-mounted turn signals only: DO NOT remove the wires from the Multilock connector pin housing under the fuel tank.. Note the wire colors and positions in each cavity of the socket housings leading from the switches. Refer to the wiring diagram and the ELECTRICAL CONNECTORS section in the Service Manual. Remove the wires from the socket housings. Models with handlebar-mounted turn signals: Note the wire colors and positions in each cavity of the Multilock socket housing leading from the turn signals. Refer to the wiring diagram and the AMP MULTILOCK ELEC- TRICAL CONNECTORS section in the Service Manual. Remove the wires from the socket housing.. Use tape to wrap the wire terminal ends from each source to make separate leaders. Wrap each leader tight enough to enter the grommet hole and pass easily through the new handlebar. Proceed to "New Handlebar Wiring". Original Handlebar Removal, FLHR, FLHRC, FLHRS Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (000a). FLHRS models only: Remove and retain the two hex head screws and flat washers attaching the chrome cover to the fork stem and bracket assembly.. All FLHR models: Using a T-0 TORX drive head, remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. FLHRS models only: Remove the cover and set it aside for re-installation.. All FLHR models: Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See FRONT BRAKE MASTER CYLINDER in the Service Manual.. Remove the old brake lines from the motorcycle. For models with handlebar-mounted turn signals, remove the plastic wiring retainer clips that secure the turn signal harnesses to the handlebar.. Using a T7 TORX drive head, remove the front-brake master cylinder and clutch-lever assemblies from the handlebar. 6. Refer to CLUTCH HAND CONTROL: REMOVAL in the Service Manual, and follow the instructions to disconnect the clutch cable from the clutch lever and side cover. Remove and discard the cable. 7. Remove the headlamp assembly from the headlamp nacelle. See HEADLAMP in the Service Manual. Molex connectors are used for the handlebar control wiring on 007 and later models. 006 and earlier vehicles use Deutsch connectors. Refer to the MOLEX ELECTRICAL CONNECTORS or DEUTSCH ELECTRICAL CONNECTORS section of the Service Manual for disconnection and re-connection procedures. 8. Disconnect the handlebar control wiring from the gray and black 6-way main harness connectors inside the headlamp nacelle. Disconnect the electronic cruise-control wiring from the two -way connectors if the vehicle is so equipped. 9. FLHRS models only: Disconnect the front turn signal wiring from the black Multilock 6-way connector. 0. All FLHR models: Refer to the HANDLEBAR SWITCHES; RIGHT HANDLEBAR CONTROLS section of the Service Manual for removal of the right-side switch housing assembly and harness. This is necessary to access the throttle cables. -J06 of 0

4 . Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables from the existing right grip/ throttle sleeve assembly.. Refer to the LEFT HANDLEBAR CONTROLS section of the Service Manual for removal of the left-side switch housing assembly and wire harness is0008a FLHRS models only: Remove and retain the Phillips pan head screw (9), nut () and flat washer (0) holding the front of the handlebar cover () and wind deflector (6) assembly. Disassemble the wind deflector from the handlebar cover. Discard the handlebar cover, but retain the wind deflector and three flange head screws (). is008 FLHRS 7. Headlamp. Handlebar cover. Fork lock plate. Nacelle (left half). Nacelle trim strip 6. Wind deflector (FLHRS only) 7. Nut 8. Flat head screw () 9. Pan head screw 0. Flat washer. Nut with washer. Flange head screw () Figure. Nacelle, Headlamp and Handlebar Cover (FLHR Models). See Figure. Reaching inside the headlamp nacelle (), remove the flange nut (7) to release the trim strip () at the top of the nacelle. 0 Retain the nut and trim strip for re-assembly.. Carefully pry off the fork-lock label plate () from the stock handlebar cover (). Remove the entire plastic plate; do not remove the adhesive label from the plate.. Remove and retain the two Phillips flat head screws (8) underneath the label plate that hold the handlebar cover to the fork lock. 6. FLHR and FLHRC models: Remove the Phillips pan head screw (9), nut () and flat washer (0) holding the front of the handlebar cover () to the nacelle. Discard the handlebar cover, but retain the screw, nut and washer. 6. Clamp screw (). Flat washer (). Upper clamp (). Handlebar. Handlebar riser () 6. Riser attaching screw () Figure. Handlebar Clamps and Risers (FLHR Models) 7. See Figure. Remove and discard the screws () and flat washers () that fasten the handlebar upper clamps () to the risers (). Discard the clamps. Remove the handlebar () from the motorcycle. 8. If the left-side hand grip is not glued to the handlebar: Remove the hand grip and set it aside for installation to the new handlebar. 9. Remove and discard the stock handlebar risers. Save the remaining hardware for later installation. S 007 and later models use Molex connectors. 006 and earlier vehicles use Deutsch connectors. Refer to MOLEX or DEUTSCH ELECTRICAL CONNECTORS in the Service Manual for terminal removal and re-installation procedures. DO NOT remove the wires from the Molex or Deutsch handlebar switch connector pin housings inside the nacelle. FLHRS models only: DO NOT remove the wires from the Multilock connector pin housing inside the nacelle. 0. Note the wire colors and positions in each cavity of the socket housings leading from the switches. Refer to the wiring diagram and the ELECTRICAL CONNECTORS section in the Service Manual. Remove the wires from the socket housings. -J06 of 0

5 FLHRS models only: Note the wire colors and positions in each cavity of the Multilock socket housing leading from the turn signals. Refer to the wiring diagram and the AMP MULTILOCK ELECTRICAL CONNECTORS section in the Service Manual. Remove the wires from the socket housing.. Use tape to wrap the wire terminal ends from each source to make separate leaders. Wrap each leader tight enough to enter the grommet hole and pass easily through the new handlebar. Proceed to "New Handlebar Wiring". New Handlebar Wiring Wiring in the switch housings must be routed exactly as shown. Pinch points in the switch housings can shortcircuit or sever wires, which could cause loss of control resulting in death or serious injury. (00b). Remove the plastic wiring retainer clips that secured both switch harnesses to the original handlebar.. See Figure 8. Slide one large grommet () onto each of the switch-wire bundles, positioning the grommet close to the switch end. For models with handlebar-mounted turn signals, slide one small grommet () onto each of the turn-signal wire bundles, positioning the grommet close to the turn signal end.. Apply a light coat of liquid soap, window cleaner, or allpurpose lubricant such as WD-0, to the right-side switch wire bundle (and turn signal wire pair, if so equipped). is08 6. Wind deflector. Wind deflector adapter. Flanged screw (). Handlebar cover. Flanged screw () 6. Flanged nut () Figure. Handlebar Cover/ Wind Deflector Assembly (FLHRS) 6 The handlebar cover on FLHR models must be placed on the handlebar risers before the wires are installed through the riser wiring holes.. For FLHR and FLHRC models, slide a new handlebar cover (purchased separately) onto the handlebar risers. For FLHRS models, see Figure. a. Assemble the saved wind deflector () to the new adapter (, purchased separately) using the three flanged screws () saved in Step. b. Tighten the screws to -8 ft-lbs (6.-. Nm). c. Assemble the new handlebar cover (, purchased separately) to the adapter using the two flanged screws () and flanged nuts (6) from the adapter kit. d. Tighten the screws to -8 ft-lbs (6.-. Nm). e. Slide the handlebar cover/ wind deflector assembly onto the handlebar risers.. For ALL models without handlebar-mounted turn signals, a. Obtain a piece of string approximately. feet (one meter) long and tie a small weight (for example, a spare nut) to one end of the string. b. Place the new handlebar on a horizontal surface so that the riser ends face upward. c. Insert the weighted end of the string into the right side riser wiring hole and tip the handlebar so that the weight slides out the right grip end of the handlebar. d. Ensure the opposite end of the string is still extending out of the riser hole. Remove the weight from the string and with a tweezers, fish the string out through the switch wiring hole. For ALL models with handlebar-mounted turn signals, a. Obtain two pieces of string that are each approximately. feet ( meter) long and tie a small weight (for example, a spare nut) to one end of both strings. b. Place the new handlebar on a horizontal surface so that the riser ends face upward. c. Insert the weighted end of the strings into the right side riser wiring hole and tip the handlebar so that the weight slides out the right grip end of the handlebar. d. Ensure the opposite ends of the strings are still extending out of the riser hole. Remove the weight from the strings. For FXDB and FXDWG models: With a tweezers, fish both strings out through the switch wiring hole. For all models EXCEPT FXDB and FXDWG: With a tweezers, fish one string out through the switch wiring hole, and the other string out the turn signal wiring hole. 6. Tie the end of the string from the right-side switch-wire hole to the switch-wire bundle. -J06 of 0

6 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. (008b) is006. Riser wiring hole. Upper switch-mounting screw. Lower switch-mounting screw. Position inside switch-edge pinch point above wires and hole in handlebar. Keep wires clear of pinch points near threaded post Figure 6. Switch-Housing Wire Routing (Right Side Shown) Ensure the turn-signal string (if present) stays in place as the switch-wire is fed through the handlebar. 7. See Figure 6. Gently feed the wire bundle into the rightside switch-wire hole and pull the bundle down through the handlebar and out the riser hole. 8. For models with handlebar-mounted turn signals, EXCEPT 007 and later FXDB and FXDWG models: Tie the end of the string coming from the turn-signal wire hole to the turn-signal wire bundle. 9. Gently feed the wire bundle into the right-side turn-signal hole and pull the bundle down through the handlebar and out the riser hole. Grommets in each of the wiring holes in the handlebar must remain in position after routing the wiring through the handlebar. Operation without the grommets in place can damage wires, causing a short circuit which could result in death or serious injury. (006d) 0. See Figure 8. Insert the switch-wire grommet () into place in the switch-wire hole in the handlebar. The round turn-signal wiring grommet is an extremely tight fit. Use a twisting motion to avoid damaging the grommet.. If present, insert the turn-signal grommet () into place in the turn-signal wire hole in the handlebar.. Slide one large grommet () onto both of the wire bundles sticking out of the riser wire hole, and insert the grommet into the riser hole in the handlebar.. Repeat steps through for the left-side switch wires and if present, the turn-signal wires.. Loosely fasten the brake-lever and clutch-lever clamps to the new handlebar.. Loosely fasten the handlebar-switch housings to the new handlebar. It is necessary to install the Front Turn Signal Mounting Kit onto FXDWG, FXST, FXSTD and FLSTF models to avoid contact between the front turn signals and the fuel tank during vehicle operation. 6. On FXDWG, FXST, FXSTD and FLSTF models, install the Front Turn Signal Mounting Kit (sold separately). 7. Remove the tape from the ends of the wire bundles. 8. Check for electrical continuity between the handlebar and each wire in the wire bundles. Continuity would indicate a short circuit, which would require examination of the wires and routing in the switch housing. 9. Proceed to "New Handlebar Installation" for your model. New Handlebar Installation, Dyna and Softail. Install the new handlebar onto the upper triple clamp using the saved hardware. Torque the riser bolts to -0 ft-lbs (- Nm). Molex connectors are used for the handlebar control wiring on 007 and later models. 006 and earlier vehicles use Deutsch connectors. Refer to the MOLEX ELECTRICAL CONNECTORS or DEUTSCH ELECTRICAL CONNECTORS section of the Service Manual for re-connection procedures.. Refer to the notes made during the removal steps, and the wiring diagram and correct ELECTRICAL CONNEC- TORS section in the Service Manual. Insert each socket terminal from the left-side wire bundle into the correct cavity of the gray socket housing removed earlier.. Insert each socket terminal from the right-side wire bundle into the correct cavity of the black socket housing removed earlier.. Connect the gray socket housing to the gray 6-way pin housing under the left side of the fuel tank. Connect the black socket housing to the black 6-way pin housing under the right side of the tank. -J06 6 of 0

7 . For models with handlebar-mounted turn signals: a. Route both turn signal wires down through the large oval opening in the center of the upper triple tree behind the front riser cover. b. Follow the routing noted earlier to the 6-way turn signal pin housing under the right side of the fuel tank. c. Refer to the notes made during the removal steps, and the wiring diagram and AMP MULTILOCK ELECTRICAL CONNECTORS section in the Service Manual. Insert each socket terminal leading from the turn signals into the correct cavity of the Multilock socket housing removed earlier. d. Install the clips and/ or wire guides saved earlier. Use wire ties from the kit to secure the turn signal wiring to the handlebar switch wiring along the route. 6. Connect the 6-way AMP socket housing to the main harness pin housing under the fuel tank. the black pin housing to the black right-hand switch control socket housing. 7. If present, connect the 6-way AMP turn-signal socket housing to the pin housing inside the nacelle. 8. If so equipped, connect the -way cruise control harnesses to the extensions in the same manner. 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. (000a) 9. Tighten the fuel tank. Refer to FUEL TANK-INSTALLA- TION (AFTER PARTIAL REMOVAL) in the appropriate section (Carbureted or EFI Engine) of the Service Manual. 0. Proceed to "New Handlebar Installation, ALL Models". New Handlebar Installation, ALL Models 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. (000a) 7. Re-install the fuel tank. Refer to FUEL TANK-INSTALLA- TION in the appropriate section (Carbureted or EFI Engine) of the Service Manual. 8. Proceed to "New Handlebar Installation, ALL Models". New Handlebar Installation, FLHR, FLHRC, FLHRS. Install the new handlebar onto the upper fork bracket using the saved hardware. Tighten the riser bolts to -0 ft-lbs (- Nm). Molex connectors are used for the handlebar control wiring on 007 and later models. 006 and earlier vehicles use Deutsch connectors. Refer to the MOLEX ELECTRICAL CONNECTORS or DEUTSCH ELECTRICAL CONNECTORS section of the Service Manual for re-connection procedures.. Refer to the notes made during the removal steps, and the wiring diagram and correct ELECTRICAL CONNEC- TORS section in the Service Manual. Insert each socket terminal from the left-side wire bundle into the correct cavity of the gray socket housing removed earlier.. Insert each socket terminal from the right-side wire bundle into the correct cavity of the black socket housing removed earlier.. For FLHRS models only: Refer to the notes made during the removal steps, and the wiring diagram and AMP MULTILOCK ELECTRICAL CONNECTORS section in the Service Manual. Insert each socket terminal leading from the turn signals into the correct cavity of the Multilock socket housing removed earlier.. Route the handlebar switch wires (and turn-signal wires if present) into the nacelle. 6. Connect the gray pin housing inside the nacelle to the gray 6-way left-hand switch control socket housing, and Wiring in the switch housings must be routed exactly as shown. Pinch points in the switch housings can shortcircuit or sever wires, which could cause loss of control resulting in death or serious injury. (00b) Avoid the switch housing pinch points as shown in Figure 6.. Refer to RIGHT HANDLEBAR SWITCH: INSTALLATION in the Service Manual, and follow the instructions given to: a. Install the throttle control cables and right grip/ throttle sleeve assembly. b. Use the T TORX drive head to install the upper and lower switch housings onto the handlebar. Do not fully tighten the screws. c. Install the brake master cylinder reservoir/ brake lever assembly and the handlebar clamp to the handlebar with the T7 TORX screws and flat washers removed earlier. The brake master cylinder must be horizontally level. Orient the lever for rider comfort and posture, and tighten first the top, then the bottom handlebar clamp screw to 7-80 in-lbs (8-9 Nm). d. Tighten first the lower, then the upper switch housing screws to - in-lbs (.0-. Nm). 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.. Install a new (purchased separately) or original handlebar grip on the left end of the new handlebar according to the handlebar grip instruction sheet or the LEFT HAND GRIP, INSTALLATION instructions in the Service Manual. -J06 7 of 0

8 . Refer to LEFT HANDLEBAR SWITCH: INSTALLATION in the Service Manual, and follow the instructions given to: a. Use the T TORX drive head to install the upper and lower switch housings onto the handlebar. Do not fully tighten the screws. b. Install the clutch cable per the Service Manual or clutch cable kit instructions. For FLHR, FLHRC and FLHRS models: Orient the clamp on the left-side fork so the loop is forward of the acorn nut. Route the clutch cable through the clamp. For FXDWG only, install the clutch cable guide kit (sold separately) along with the clutch cable. c. Install the clutch-lever assembly and the handlebar clamp to the handlebar with the T7 TORX screws and flat washers removed earlier. Orient the lever for rider comfort and posture, and tighten first the top, then the bottom handlebar clamp screw to inlbs ( Nm). d. Tighten first the lower, then the upper switch housing screws to - in-lbs (.0-. Nm).. Verify that the right grip/ throttle sleeve rotates and returns freely and does not bind on the handlebar or switch housing at both left and right fork stops. Proceed to "Final Assembly". FINAL ASSEMBLY FLHRS Original headlamp. New handlebar cover (FLHR, FLHRC). Original fork lock plate. Original nacelle (left half). Nacelle trim strip 6. Original nut 7. Original flat head screw () 8. Original pan head screw 9. Original flat washer 0. Original nut with washer. Handlebar cover/ wind deflector assembly (FLHRS) 7 9 is097a Figure 7. Nacelle, Headlamp and New Handlebar Cover (FLHR Models). For FLHR and FLHRC models: See Figure 7. Slide the handlebar cover (item, installed earlier) down onto the nacelle. For FLHRS models: See Figure 7 inset. Slide the handlebar cover/ wind deflector assembly (item, installed earlier) down onto the nacelle.. Obtain the pan head Phillips screw (8), nut (0) and flat washer (9) removed earlier.. Insert the screw through the hole at the front of the handlebar cover and the top of the headlamp nacelle ().. Reach inside the nacelle and install the nut and flat washer onto the screw threads. Tighten the screw to 0-0 in-lbs (.-. Nm).. Install the two flat head Phillips screws (7) removed earlier to secure the handlebar cover to the fork lock. Tighten the screws to 0-0 in-lbs (.-. Nm). 6. Press the original fork-lock label plate () into position on the handlebar cover. -J06 8 of 0

9 7. Obtain the chrome nacelle trim strip and serrated flange nut removed earlier. For FLHR and FLHRC models: Insert the hook on the trim strip into the slot on the handlebar cover. For FLHRS models: Insert the hook on the trim strip into the slot on the wind deflector. Insert the weld stud on the trim strip into the hole at the top of the headlamp nacelle, and reach inside the nacelle to install the flange nut. Tighten the nut to -0 in-lbs (.7-. Nm). 8. Install the headlight into the nacelle. See HEADLAMP ASSEMBLY-INSTALLATION in the Service Manual. 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. (008a) Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00a) 9. Carefully inspect the brake line for damage or defects, and replace the brake line if damaged. Install the brake line per the Service Manual instructions or the instructions included with the Brake Line Kit. 0. Bleed the brakes. See BLEEDING HYDRAULIC BRAKES in the Service Manual.. Install a new clutch cable (sold separately) per the CLUTCH HAND CONTROL instructions in the Service Manual. SAFETY CHECK 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. (007a) Be sure wires, clutch cables, throttle/ idle cables and brake lines do not pull tight when handlebars are turned fully to left or right fork stops. 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). Verify that the Ignition/ Light Key Switch is turned to the OFF position. Apply a light coat of petroleum jelly or corrosion retardant material to the battery terminals. Refer to the Service Manual and follow the instructions given to re-attach the battery cables (positive cable first). Be sure that all lights and switches operate properly before operating motorcycle. Low visibility of rider can result in death or serious injury. (006a). Turn the Ignition/Light Key Switch to IGNITION, but do not start the motorcycle. Test each handlebar switch for proper operation.. For 00 and earlier FXDL and FXDWG models: Be sure plug in lower forward section of rear fender is installed. Operation without plug installed could allow tire contact with wiring harness. Tire contact with wiring harness can cause wire damage, which could result in death or serious injury. (006b) Inspect the lower forward section of the fender inside the rear wheel well. A three-inch (76 mm) square hole in the fender should be covered with a rubber plug. If the plug is damaged, loose or missing, it MUST be replaced (Part Number 90-90, available from a Harley-Davidson dealer). Without this plug in place, the wire harness could come out of the opening and contact the rear tire, causing rear lighting failure or other serious electrical problems.. For ALL models: Turn the handlebar to the left and right steering stops, testing the handlebar control functions at each stop.. Apply the front brake hand lever to test operation of the brake lamp. 6. Refer to the Service Manual, and follow instructions to install the seat. 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) 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. (0090a) 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. (0089a) -J06 9 of 0

10 SERVICE PARTS is00 Item Handlebar, Street Slammer Handlebar grommet, large () Handlebar grommet, small () Figure 8. Service Parts Table. Service Parts Table Description (Quantity) Part Number Not Sold Separately J06 0 of 0