Arlen Ness RAD III User manual

6050DublinBoulevard,Dublin,Ca.94568‐Technicalassistance:925.479.6379‐www.arlenness.com
RADIIIHANDLEBARCONTROLS
For96‐upHarleyDavidsonmodels
ThankyouforpurchasingthisArlenNessproduct.Webelievethatourproductsaretheverybestavailableandareengineered
toprovidealifetimeofuse.Basichandtoolsandaservicemanualforyouryearandmodelmotorcycleareallyouneedtocom‐
pletethisinstallation.
Parts:
1‐Brakemastercylinderassembly
1‐Clutchperchassembly
1‐Switchhousingset
1‐lowerleftswitchhousing(foraudioonly08‐748kitonly)
1‐Hardwarekit
1‐Instructions
1.Disconnectnegativebatterycable.Confirmthebikehasnopower.

2.RemoveOEMmirrorsandturnsignalsfromclutchperchandbrakemastercylinder.(ifsoequipped) 

3.Startwiththethrottleside:    
(Allmodelsexcept08‐uptouring)Slackthrottlecablealltheway.Removeupperandlowerswitchhousing
screws.Lifttheupperswitchhousingupandrotateitforwardtogainaccesstothethrottlecableends.Remove
thecableendsfromthegripandremovegrip.    
(08‐uptouring)Removeupperandlowerswitchhousingscrews.Lifttheupperswitchhousingupandrotateitfor‐
ward,pushthelowerhousingdownandcarefullyremovegrip.

IMPORTANTNOTE:Duringthenextstepit’simportantnottogetbrakefluidonanypaintedsurfaces.Itwilldam‐
agepaint!Ifyougetbrakefluidonthepaintwashitoffimmediately.

4.Breakbanjoboltlooseatthemastercylinderthensnugitbackdownsoitdoesnotleak.Removemastercylinder
fromhandlebarandremovebrakeline.Securebrakelinepointingstraightupsoitdoesnotdrip.  

5.(Allmodelsexcept08‐uptouring)Removethrottlecablesfromlowerswitchhousing.

6.NOTE:Duringthissteppaycloseattentiontohowthewiresarerouted,howthewiresaresecuredandbasically
howeverythingfitsinsideofthehousingsbeforedisassembly.Thiswillhelpduringreassembly.RemoveOEM
switchesandbuttonsfromOEMswitchhousingstheninstallthemintotheRADIIIhousingsinreverseorderofre‐
moval.

7.(Allmodelsexcept08‐uptouring)Afteralltheswitchesandbuttonsareinstalledintonewswitchhousingsinstall
throttlecablesintolowerswitchhousing.Installthethrottlegripthenattachcablestoit.
(08‐uptouring)Afteralltheswitchesandbuttonsareinstalledintonewswitchhousingsinstallthethrottlegrip.

8.Positionswitchhousingsaroundgripandstartscrewsbutdonottighten.NOTE:Besurenottopinchanywires.

9.Attachbrakelinetonewmastercylinderusingnewbanjoboltandsealwashers(provided).Snugfornow.Attach
newmastercylindertohandlebarsmakingsuretoengagetabonlowerswitchhousingingrooveinmastercylin‐
der.Rotatecontroltodesiredpositionthenstartingwithtop,torqueboltsto6‐7ft.lbs.

6050DublinBoulevard,Dublin,Ca.94568‐Technicalassistance:925.479.6379‐www.arlenness.com
RADIIIHANDLEBARCONTROLS
For96‐upHarleyDavidsonmodels
12.Torqueupperandlowerswitchhousingscrewsto35‐45in‐lbs.
13.Torquebanjoboltto13‐15ft‐lbs.
14.(Allmodelsexcept08‐uptouring)AdjustthrottlecablesasperOEMpro‐
cedure.
15.Fillthemastercylinderreservoirwiththeappropriatetypeofbrakefluid
thenbleedsystem.
16.Movetoclutchside:
Slackclutchcablealltheway.Removeclutchleverpivotpinthenremove
leverandcablefromperch.Removeclutchcableanchorpinfromlever
thenremovecablefromlever.
17.Removeupperandlowerswitchhousingscrewsthenremoveclutchperch
assemblyfromhandlebars.
18.NOTE:Duringthissteppaycloseattentiontohowthewiresarerouted,
howthewiresaresecuredandbasicallyhoweverythingfitsinsideofthe
housingsbeforedisassembly.Thiswillhelpduringreassembly.Remove
OEMswitchesandbuttonsfromOEMswitchhousingstheninstallthem
intotheRADIIIhousingsinreverseorderofremoval.
19.Positionswitchhousingsaroundgripandstartscrewsbutdonottighten.
NOTE:Besurenottopinchanywires.
20.Removeclutchleverfromnewperchassemblyandsetaside.Installperch
ontohandlebarsmakingsuretoengagetabonlowerswitchhousingin
grooveatthebottomofperch.NOTE:makesurenottopinchanywires.
Rotatecontroltodesiredpositionthenstartingwithtop,torqueboltsto6‐
7ft.lbs.
21.Torqueupperanlowerswitchhousingscrewsto35‐45in‐lbs.
22.Forthisnextstepyouwillneedtoremovethederbycoverthenloosenthe
clutchpushrodadjustingscrewalltheway.NOTE:Thebikemustbestand‐
ingstraightuporprimaryfluidwillspilloutofprimarywhenyouremove
thederbycover.
23.Insertcableendinnewleverandretainwithanchorpin.Pic1.
24.NowwithaslightbendintheendoftheclutchcablePic2.NOTE:Donot
kinkcable.InstallthecablehousingintoperchfirstPic3makingsurethe
cablehousingseatscompletelyintoperch.Thenpulltheleverw/cable
aroundthefrontoftheperchintoplacetheninstallpivotpinandretaining
ringtosecurePic4.
25.AdjustclutchasperOEMprocedure.Reinstallderbycoverwithnewgasket
oro‐ring.
26.Reconnectthebatterynegativecable.Testallswitchesandbuttonstocon‐
firmproperfunction.
27.Installmirrorsandturnsignalsifequipped.
Pic1

Lever

Anchorpin

Cableend

Pic2Cablehousing

Slightbend
Pic3

Cablehousing



Frontofperch

Leverw/cable
Pic4
Pivotpin