Buell N1050.1AK User manual

-J04491 2008-10-10
HEATED HAND GRIP KIT
GENERAL
Kit Number
N1050.1AK
Models
For model fitment information, see the Accessories section
of www.buell.com (English only).
Tools and Supplies Required
For Lightning and Ulysses Models: Loctite®271
Threadlocker and Sealant - Red (H-D Part Number 99671-97)
is required for the proper installation of this kit.
WARNING
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
Buell dealer perform the installation. Improper installation
of this kit could result in death or serious injury. (00334a)
NOTE
This instruction sheet references service manual information.
A service manual for this model motorcycle is required for
this installation and is available from a Buell dealer.
Electrical Overload
NOTICE
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 Buell dealer for advice
about the amount of current consumed by additional
electrical accessories, or for necessary wiring changes.
(00249b)
WARNING
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. (00310a)
The heated hand grips require up to 3.0A additional current
from the electrical system.
Kit Contents
See Figure 17 and Table 1.
PREPARATION
1. Refer to the service manual, and follow the instructions
given to remove the seat. Unthread the fastener and
remove the negative (black) battery cable from the
negative (-) battery terminal.
2. For Firebolt models: Fairing removal is not necessary
in order to install this kit. For Lightning models: Remove
the four screws and washers retaining the windscreen
to the vehicle with a 1/8 inch hex key. Set the screen
and hardware aside for later assembly. For Ulysses
models:For 1125R models:For 1125CR models: Using
a T-30 TORX®drive head, remove the two button head
screws and nylon washers fastening the flyscreen to the
headlight housing.
a. Remove the six screws and washers retaining the
flyscreen/windscreen assembly to the vehicle with a
1/8 inch hex key. Set the screen and hardware aside
for later assembly.
b. Unsnap the deflectors from the handlebar end caps,
and loosen the deflector attaching screws if necessary
to swivel the deflectors forward.
a. Remove the four hex locknuts retaining the fairing and
the mirror/turn signal assemblies to the upper part of
the fairing bracket with a 10mm socket.
b. Disconnect the two sets of individual terminals on
each turn signal harness. Remove the mirror/turn
signal assemblies and set aside for later assembly.
c. Remove the two button head screws and nylon
washers fastening the fairing to the lower part of the
fairing bracket using a T-30 TORX®drive head.
HAND GRIP REMOVAL
1. For Firebolt, Lightning, 1125R and 1125CR models:
Begin at Step 3. For Ulysses models: Release the
switch housing harnesses from the handlebar by
removing the four harness retainers from the holes in
the bar.
NOTE
In the following step, remove only the cable straps, not the
harness retainers on the switch harness.
2. To aid in later assembly, make marks on the brake switch
harness at the approximate locations of the cable straps
that bind together the right side handlebar switch harness
and brake switch harness. Cut these cable straps off and
discard them.
3. For ALL models: Note the routing of the right side
handlebar switch wiring, and the location of any
remaining cable straps attaching the right side handlebar
switch harness to components under the
fairing/flyscreen/windscreen. Remove and discard these
cable straps.
1 / 9
Many Harley-Davidson® Parts & Accessories are made of plastics and metals which can be recycled.
-J04491
Please dispose of materials responsibly.

4. Remove the left side handlebar switch assembly
fasteners, and set aside for later assembly. Remove the
switch assembly from the handlebar.
5. Using a sharp blade or knife, carefully cut the left side
grip from the handlebar. Thoroughly clean the handlebar
surface of all dirt and adhesive residue.
6. Refer to the service manual, and follow the instructions
to disassemble the throttle and idle cables at the
handlebar end only. Disconnect the switch connector
from the vehicle harness, and remove and discard the
right side handlebar switch assembly.
7. Remove and discard the right side hand grip (throttle
grip).
HEATED HAND GRIP INSTALLATION
1. Using a 5mm hex key (1125R and 1125CR models) or
8mm socket (all other models), loosen the clutch lever
pinch screw to allow the clutch lever bracket to rotate on
the handlebar.
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5
1
2
3
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Drilling fixture1.
Set screw2.
Drilling locator holes (2)3.
Handlebar left end4.
Switch housing locating hole5.
Figure 1. Position Drilling Fixture on Left Side of
Handlebar
NOTE
Cover the front fender and intake cover (and on 1125R and
1125CR models, the left side radiator cover) with clean shop
towels to prevent scratching of the finish.
2. See Figure 1. Obtain the drilling fixture (1) from the kit.
Check that the set screw (2) does not extend into the
bore of the fixture. With the set screw inboard and toward
the front, slide the fixture onto the left end of the
handlebar (4). Align the set screw with the switch housing
locating hole (5) in the handlebar, and tighten the set
screw securely.
3. Rotate the clutch lever bracket upward to provide
clearance for the drill. Insert the 9/64 inch drill bit from
the kit into one of the holes (3) in the fixture, and drill a
hole completely through the handlebar wall. Insert the
drill bit into the second hole (3) in the fixture, and drill a
hole through the handlebar wall, directly opposite the
first hole. Remove the fixture from the handlebar.
Thoroughly clean the handlebar surface of all metal
shavings from the drilling operation.
NOTE
Take care not to break the alignment pins on the switch
housings.
4. See Figure 17. Obtain the left side heated hand grip (1)
and two self-tapping screws (8) from the kit, and note
the two slots on the inboard end of the grip. With the wire
facing down, slide the grip onto the left end of the
handlebar, aligning the holes inside the slots with the
holes drilled in the handlebar in Step 3. Peel back the
collar on the hand grip, and insert one of the screws into
each slot, with the threads protruding through the hole
in the grip and into the hole in the handlebar. Fasten the
screws into the holes in the handlebar using a T-20
TORX®drive head. Tighten to 1.6–1.8 N·m
(14–16 in-lbs).
5. Refer to the service manual, and follow the instructions
to install the left side handlebar switch assembly to the
handlebar.
6. Rotate the clutch lever bracket downward into its original
position. On 1125 CR models only, line up the clutch
lever bracket with the reference lines on the handlebar.
For ALL models, tighten the clutch lever pinch screw
to 6.8–9.5 N·m (60–84 in-lbs).
NOTE
For Ulysses models only: If a Buell™ Quest™ Global
Positioning System (GPS) Kit is installed on the vehicle, fit
the heated throttle grip wire between the two GPS wires.
7. Obtain the new right side handlebar switch assembly
and heated throttle grip from the kit. With the wire facing
down, slide the grip onto the right end of the handlebar.
Refer to the service manual to install the throttle grip,
throttle and idle cables and handlebar switch assembly
to the vehicle. DO NOT fasten wires and cables to the
vehicle at this time.
8. For Lightning and Ulysses models: For Firebolt
models: For 1125R models: For 1125CR models:
a. Slightly loosen the four screws fastening the upper
handlebar clamp.
b. Shift the position of the handlebar as needed to
allow threading the heated throttle grip wire and
right side handlebar switch harness under the
handlebar, behind the front fork, following the path
of the existing wiring into the front fairing. Note that
the rubber-mounted gauge cluster may need to be
pushed upward slightly on the right side to allow
the switch connector to be fed under the cluster.
c. One at a time, remove the handlebar clamp
screws. Refer to the service manual, Chapter 1,
for instructions on re-using of fasteners with
threadlocking agents.
d. Clean the screw and hole. Apply two drops of
Loctite®271 (Red) Threadlocker and Sealant to
the screw threads, and install the screw, but do not
fully tighten. Repeat for the remaining screws.
e. Align the handlebar for rider comfort. Tighten both
front screws to 14–16 N·m (10–12 ft-lbs), then
tighten both rear screws to 14–16 N·m
(10–12 ft-lbs).
f. Remove the cable straps attaching the left and right
side handlebar switch wiring harnesses to the
upper fork clamp (triple clamp).
2 / 9 -J04491

g. Route the right side switch wiring harness along
the same path as the original switch wires, outside
the opening between the frame and the fairing
support bracket.
h. Route both heated grip harnesses through the
opening between the frame and the fairing support
bracket. Continue routing the right side handlebar
switch wiring harness and both heated grip
harnesses along the vehicle main wire harness to
the connector location behind the headlight
assembly.
i. Route the right side switch wiring harness along
the same path as the original switch wires, through
the opening in the fairing support bracket.
j. Route the right side heated grip harness through
the same opening in the fairing support bracket.
k. Continue routing the right side handlebar switch
wiring harness and heated grip harness along the
vehicle main wire harness to the connector location
beneath the headlight assembly.
l. Route the right side switch wiring harness along
the same path as the original switch wires, through
the opening in the headlight housing.
m. Route the right side heated grip harness through
the same opening in the headlight housing.
NOTE
For ALL models: A "hanging loop" of excess wire is
important to maintain continued function of the right side
heated hand grip as it is subjected to throttle operation.
n. Continue routing the right side handlebar switch
wiring harness and heated grip harness along the
vehicle main wire harness to the connector location
beneath the headlight assembly.
9. See Figure 2. Locate the mark (1) on the right side hand
grip wire, and align it with the inboard edge (2) of the
handlebar switch. This will allow sufficient slack in the
wire to prevent binding of the wire during throttle
operation. For Lightning and Ulysses models: Use a
cable strap (3) from the kit to bind the right side hand
grip wire to the throttle and idle cables just inboard of the
throttle cable adjusters, as shown. For Firebolt and
1125R models: Use a cable strap (3) from the kit to
bind the right side hand grip wire to the handlebar switch
harness, as shown in Figure 3. For 1125CR models:
Use a cable strap (3) from the kit to bind the right side
hand grip wire to the handlebar switch harness and turn
signal wire, similar to Figure 3, which shows the 1125R
model.
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3
1
is04644
Mark on right side hand grip wire1.
Inboard edge of handlebar switch2.
Strap wire to cables at this location3.
Figure 2. Bind Heated Grip Wire to Throttle and Idle
Cables (Ulysses Model Shown)
is04882
Figure 3. Bind Heated Grip Wire to Handlebar Switch
Harness (1125R Model Shown)
10. With the first cable strap installed, rotate the right side
hand grip to make sure the wire does not touch any part
of the hand control. If the wire DOES touch the hand
control at any point, increase the size of the loop as
needed to prevent contact during throttle operation.
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2
1
is04684
Strap right side wiring to upper fork clamp1.
Upper fork clamp2.
Strap left side wiring to upper fork clamp3.
Figure 4. Bind Wiring to Upper Fork Clamp (Firebolt
Models)
NOTE
A "hanging loop" of excess wire on the left side grip is used
to prevent kinking of the wire and provide a balanced
appearance to the right side.
-J04491 3 / 9

11. For Firebolt models: See Figure 4. Use a second cable
strap (1) to bind the right side heated hand grip wire,
handlebar switch harness and brake switch harness to
the upper fork clamp (2). For Lightning models: Use a
second cable strap to bind the right side heated hand
grip wire, handlebar switch harness and brake switch
harness together behind the upper fork clamp. DO NOT
bind the wires to the upper fork clamp. For Ulysses
models: See Figure 5. Use a second cable strap (2) to
bind the right side heated hand grip wire to the handlebar
switch harness and brake switch harness (3) at the
(lower) mark made on the handlebar switch harness in
Step 5. For 1125R models: See Figure 6. Hook the right
side heated hand grip wire, handlebar switch harness
and brake switch harness into the wire guide under the
right side of the upper fork clamp. For ALL models: Test
the throttle operation to verify that there is NO contact
between the hand grip wire and any part of the vehicle.
2
3
1
is04645
Wire previously strapped to cables1.
Strap wire to brake and control harnesses at
this location
2.
Brake and hand control harnesses3.
Figure 5. Bind Heated Grip Wire to Brake and Handlebar
Switch Harnesses (Ulysses Models)
is04883
Figure 6. Hook Wiring to Wire Guide (1125R Models)
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1
is04646
Mark on left-side hand grip wire1.
Inboard edge of handlebar switch2.
Figure 7. Align Mark with Edge of Switch (Ulysses Model
Shown)
12. See Figure 7. Locate the mark (1) on the left side hand
grip wire, and align it with the inboard edge (2) of the
handlebar switch. For Firebolt models: Use a cable
strap from the kit to bind the left side hand grip wire,
handlebar switch harness and clutch interlock switch
harness together. See Figure 4. Use a second cable
strap (3) to bind the heated hand grip wire, handlebar
switch harness and interlock switch harness to the upper
fork clamp (2). For Lightning models: Use a cable strap
from the kit to bind the left side hand grip wire, handlebar
switch harness and clutch interlock switch harness to
the handlebar, close to the switch assembly. Use a
second cable strap to bind the heated hand grip wire,
handlebar switch harness and interlock switch harness
to the handlebar, close to the upper fork clamp. DO NOT
bind the wires to the upper fork clamp. For Ulysses
models: For 1125R models:For 1125CR models:
a. See Figure 8. Use two cable straps (1 and 2) from
the kit to bind the left side hand grip wire (3) to the
handlebar switch harness and clutch interlock
switch harness on either side of the harness
retainers (4).
b. If the prongs on any of the harness retainers were
broken during disassembly, replace them with the
new harness retainers from the kit. Press the
harness retainers into the holes in the left and right
sides of the handlebar.
c. Use a cable strap from the kit to bind the left side
hand grip wire and handlebar switch harness
together.
d. Hook the left side heated hand grip wire, handlebar
switch harness and clutch interlock switch harness
into the wire guide under the left side of the upper
fork clamp.
e. Route the left side switch wiring harness along the
same path as the original switch wires, through
the opening in the fairing support bracket.
f. Route the left side heated grip harness through
the same opening in the fairing support bracket.
g. Continue routing the left side handlebar switch
wiring harness and heated grip harness along the
vehicle main wire harness to the connector location
beneath the headlight assembly.
4 / 9 -J04491

h. Use a cable strap from the kit to bind the left side
hand grip wire, turn signal wire and handlebar
switch harness together.
i. Route the left side switch wiring harness along the
same path as the original switch wires, through
the opening in the headlight housing.
j. Route the left side heated grip harness through
the same opening in the headlight housing.
k. Continue routing the left side handlebar switch
wiring harness and heated grip harness along the
vehicle main wire harness to the connector location
beneath the headlight assembly.
1
3
2
4
is04647
Cable strap1.
Second cable strap2.
Heated grip wire3.
Harness retainer (2)4.
Figure 8. Bind Heated Grip Wire to Handlebar Switch
Harness (Ulysses Models)
13. For Firebolt models: Proceed to Step 14. For Lightning
models: Proceed to Step 18. For Ulysses models:
Proceed to Step 23. For 1125R models: Proceed to
Step 28. For 1125CR models: Proceed to Step 33.
HEATED HAND GRIP WIRE CONNECTION,
FIREBOLT MODELS
1. Proceed to the area under the fairing. See Figure 9. Refer
to the service manual, and follow the instructions to
connect the black four-way socket housing on the right
side handlebar switch assembly to vehicle harness pin
housing [22A] (1). If previously disconnected, connect
the black eight-way socket housing on the left side
handlebar switch assembly to vehicle harness pin
housing [24A].
1
5
4
3
2
is04685
Right side handlebar switch connector to
vehicle harness
1.
Auxiliary power connector on vehicle harness2.
Auxiliary power connector on handlebar
switch harness
3.
Protective plug installed to handlebar switch
harness
4.
Heated grip to handlebar switch harness
connectors (2) tucked between headlights
5.
Figure 9. Connect Heated Grip and Handlebar Switch
Wiring (Firebolt Models)
2. Locate the gray auxiliary power connector [160] (2) on
the main vehicle harness. Remove the protective plug,
and connect the gray pin housing (3) at the end of the
right side handlebar switch harness to socket housing
[160B]. Install the protective plug to the gray socket
housing (4) at the end of the right side handlebar switch
harness.
3. Connect the two three-way heated hand grip wire pin
housings to the two socket housings at the end of the
right side handlebar switch harness. Tuck the two heated
grip wire connectors (5) up between the headlights.
4. Obtain two cable straps from the kit, and secure the
bundle of wires and connectors beneath the dash.
Proceed to the RETURN TO SERVICE section.
HEATED HAND GRIP WIRE CONNECTION,
LIGHTNING MODELS
1. Proceed to the area behind the windscreen. See Figure
10. Route the right side heated grip wire (1) and right
side handlebar switch harness (2) behind the turn signal
flasher (3) and out over the horn (4). Refer to the service
manual for instructions to connect the black four-way
socket housing on the right side handlebar switch
assembly to vehicle harness pin housing [22A]. If
previously disconnected, connect the black eight-way
socket housing on the left side handlebar switch
assembly to vehicle harness pin housing [24A].
-J04491 5 / 9

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2
1
3
6
5
is04686
Right side heated hand grip wire1.
Right side handlebar switch harness2.
Turn signal flasher3.
Horn4.
Instrument cluster connector5.
Auxiliary power connector [160]6.
Figure 10. Connect Heated Grip and Handlebar Switch
Wiring (Lightning Models)
2. Route the left side heated grip wire and one heated
hand grip wire from the right side switch wire harness
(2) behind the instrument cluster connector (5) under the
center dash casting. Connect the grip wire three-way pin
housing to the socket housing at the end of the switch
harness. Connect the right side heated hand grip wire
pin housing to the remaining three-way socket housing
at the end of the right side handlebar switch harness.
3. Locate the gray auxiliary power connector [160] (6) on
the main vehicle harness. Remove the protective plug,
and connect the gray pin housing at the end of the right
side handlebar switch harness to socket housing [160B].
Install the protective plug to the gray socket housing at
the end of the right side handlebar switch harness.
NOTE
Do not allow the wiring to rest on the horn. Horn volume and
tone quality will be affected.
4. Tuck the two heated hand grip wire connectors behind
the turn signal flasher (3).
5. Obtain a cable strap from the kit, and loop it around the
turn signal flasher mount to capture the bundle of wires
and connectors beneath, and secure them to the mount,
holding them away from the horn. Proceed to the FINAL
ASSEMBLY section.
HEATED HAND GRIP WIRE CONNECTION,
ULYSSES MODELS
1. Proceed to the area under the flyscreen. On the right
(throttle control) side: See Figure 11. Obtain a cable
strap (1) from the kit, and attach the new right side
handlebar switch harness (2) and heated hand grip wire
(3) in the same manner as the strap removed in HAND
GRIP REMOVAL, Step 3. On the left (clutch control)
side: See Figure 12. Obtain a cable strap from the kit,
and attach the heated hand grip wire to the left side
handlebar switch harness in the location shown.
3
1
2
is04648
Cable strap1.
Right side handlebar switch harness2.
Right side heated hand grip wire3.
Figure 11. Bind Right Side Harness and Wire (Ulysses
Models)
is04649
Figure 12. Bind Left Side Harness and Wire (Ulysses
Models)
2. Refer to the service manual for instructions to connect
the black four-way socket housing on the right side
handlebar switch assembly to vehicle harness pin
housing [22A]. If previously disconnected, connect the
black eight-way socket housing on the left side handlebar
switch assembly to vehicle harness pin housing [24A].
3. See Figure 13. Route the left side heated grip wire and
one heated hand grip wire from the right side switch wire
harness (1) behind the instrument cluster connector (4)
attached to the center dash casting. Connect the
three-way pin housing on the grip wire (3) to the socket
housing at the end of the switch harness. Connect the
right side heated hand grip wire pin housing (3) to the
remaining three-way socket housing at the end of the
right side handlebar switch harness.
6 / 9 -J04491

1
3
5
3
4
2
6
2
is04650
Right side handlebar switch harness1.
Heated grip connector on right side switch
harness (2)
2.
Heated grip wire pin housing (2)3.
Instrument cluster connector4.
Auxiliary power connector [160]5.
Gray connector on right side switch harness
(2)
6.
Figure 13. Heated Grip and Auxiliary Power Connections
(Ulysses Models)
4. Separate the two halves of the gray connector [160] (5)
that provides power to the auxiliary power outlet on the
instrument panel. If connector [160] appears as shown:
Plug the two gray connectors (6) at the end of the right
side handlebar switch harness into the mating halves of
connector [160]. If a Buell™ Quest™ Global
Positioning System (GPS) Kit is installed on the
vehicle, it is already plugged in to socket housing [160B].
Proceed as follows: The final connection (without GPS
Kit installed) should look like Figure 14.
a. Disconnect the GPS wire from the vehicle main
harness socket housing [160B].
b. Plug the right side handlebar switch harness pin
housing into the vehicle main harness socket
housing [160B].
c. Plug the right side handlebar switch harness socket
housing into the GPS wire pin housing.
5. Obtain a cable strap from the kit, and loop it around the
upper dash casting to capture the bundle of wires and
connectors beneath, and secure them to the dash (see
Figure 15 ). Proceed to the FINAL ASSEMBLY section.
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2
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Auxiliary power connectors1.
Heated grip connectors on right side switch
harness
2.
Figure 14. Heated Grip Connections to Auxiliary Power
(Ulysses Models)
is04652
Figure 15. Secure Wiring to Dash (Ulysses Models)
HEATED HAND GRIP WIRE CONNECTION,
1125R MODELS
1. Proceed to the area under the headlights. See Figure
17. Obtain the "fir tree" type anchored cable strap (7)
from the kit. Install the "fir tree" anchor to the fairing
support in place of the anchored cable strap removed in
HAND GRIP REMOVAL, Step 3. Bring all of the wire
harnesses under the headlights forward, and bind with
the new anchored cable strap.
2. Refer to the service manual, and follow the instructions
to connect the black four-way socket housing on the right
side handlebar switch assembly to vehicle harness pin
housing [22A]. If previously disconnected, connect the
black eight-way socket housing on the left side handlebar
switch assembly to vehicle harness pin housing [24A].
3. Locate the gray auxiliary power connector [160] on the
main vehicle harness. Remove the protective plug, and
connect the gray pin housing at the end of the right side
handlebar switch harness to socket housing [160B].
Install the protective plug to the gray socket housing at
the end of the right side handlebar switch harness.
4. Connect the two three-way heated hand grip wire pin
housings to the two socket housings at the end of the
right side handlebar switch harness.
NOTE
In the following step, DO NOT include the four turn signal
wires in the wire bundle.
-J04491 7 / 9

5. Obtain a cable strap (6) from the kit. Loop the bundle of
wires and connectors beneath the headlights back over
itself, and secure with the cable strap. Tuck the wire and
connector bundle up between the headlights. Proceed
to the FINAL ASSEMBLY section.
HEATED HAND GRIP WIRE CONNECTION,
1125CR MODELS
1. Proceed to the area behind the flyscreen. Refer to the
service manual, and follow the instructions to connect
the black four-way socket housing on the right side
handlebar switch assembly to vehicle harness pin
housing [22A]. If previously disconnected, connect the
black eight-way socket housing on the left side handlebar
switch assembly to vehicle harness pin housing [24A].
2. Locate the gray auxiliary power connector [160] on the
main vehicle harness. Remove the protective plug, and
connect the gray pin housing at the end of the right side
handlebar switch harness to socket housing [160B].
Install the protective plug to the gray socket housing at
the end of the right side handlebar switch harness.
3. Connect the two three-way heated hand grip wire pin
housings to the two socket housings at the end of the
right side handlebar switch harness.
NOTE
In the following step, DO NOT include the four turn signal
wires in the wire bundle.
4. Obtain a cable strap (6) from the kit. Loop the bundle of
wires and connectors back over itself, and secure with
the cable strap. Proceed to the FINAL ASSEMBLY
section.
FINAL ASSEMBLY
1. For Lightning models: Position the windscreen onto
the left and right front modules. Install the four screws
and washers removed earlier, and tighten to 1.1–1.4 N·m
(10–12 in-lbs). For Ulysses models:For 1125R
models:For 1125CR models: Position the flyscreen
onto the headlight housing. Loosely fasten the flyscreen
to the headlight housing with the two button head screws
and nylon washers removed earlier. Align the flyscreen
with the headlight for best appearance, then tighten the
screws to 5.6–6.1 N·m (50–54 in-lbs).
a. Position the flyscreen/windscreen assembly onto
the left and right front modules. Install the six
screws and washers removed earlier, and tighten
to 1.1–1.4 N·m (10–12 in-lbs).
b. Snap the deflectors onto the handlebar end caps.
If loosened, tighten the deflector attaching screws
to 2.7–4.1 N·m (24–36 in-lbs).
c. Position the fairing assembly onto the fairing
support. Loosely fasten the fairing to the lower part
of the fairing bracket with the two button head
screws and nylon washers removed earlier.
d. Obtain one of the mirror/turn signal assemblies
removed earlier. Feed the turn signal wire harness
through the middle hole in the upper part of the
fairing, and down the inside of the fairing support
arm, between the fairing and support. See Figure
16. Position the harness in the cutaway areas
provided to avoid pinching between the fairing and
support.
e. Insert the mirror mounting studs through the two
outer holes in the fairing and support. Loosely
fasten the mirror/turn signal assembly to the
support with the four hex locknuts removed earlier.
f. Repeat Steps 1b and 1c with the remaining
mirror/turn signal assembly. Align the fairing and
the mirror/turn signal assemblies for best
appearance, and tighten the four locknuts to
8–11 N·m (72–96 in-lbs). Tighten the two button
head screws to 13–14.5 N·m (115–128 in-lbs).
g. Connect the violet and black wires on the vehicle
harness to the left side turn signal. Connect the
brown and black wires on the vehicle harness to
the right side turn signal.
is04885
Figure 16. Position Turn Signal Wire In Fairing Support
RETURN TO SERVICE
1. For ALL Models: Be sure wires, clutch cable, throttle/idle
cables and brake lines do not pull tight when handlebars
are turned fully to left or right fork stops
NOTICE
Do not over-tighten bolts on battery terminals. Use
recommended torque values. Over-tightening battery
terminal bolts could result in damage to battery terminals.
(00216a)
2. Verify that the ignition/headlamp key switch is turned to
the OFF position. Apply a light coat of Harley-Davidson
electrical contact lubricant (part number 99861-02),
petroleum jelly or corrosion retardant material to the
battery terminal. Thread the fastener through the negative
battery cable (black) into the threaded hole of the
negative (-) battery terminal. Tighten the fastener to
8–11 N·m (72–96 in-lbs).
3. Refer to the service manual, and follow the instructions
given to install the seat.
WARNING
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)
NOTE
The heated hand grips will take a few minutes before they
begin to feel warm.
8 / 9 -J04491

4. Turn the ignition/headlamp key switch to ON, but do not
start the motorcycle. Test each handlebar switch for
proper operation. Test for proper headlamp, turn signal,
tail lamp and stop lamp operation. Turn the handlebar
to the left and right steering stops, testing the handlebar
control functions at each stop.
5. Turn the throttle and idle cable adjusters in the direction
that will shorten the cable housings. See the service
manual, and follow the instructions to adjust the throttle
and idle cables.
SERVICE PARTS
Table 1. Service Parts Table
Part NumberDescription (Quantity)Item
N0050.5AAHand grip, heated (left side)1
N0051.5AAHand grip (throttle grip), heated (right side)2
N0158.5AAHandlebar control assembly, right side3
C2031.1AKDrilling fixture kit (includes cone-point set screw)4
70345-84Retainer, wire harness (4)5
Y0303.2BCable strap, straight (7)6
10177Cable strap, anchored ("fir tree" type)7
CA0044.3AKScrew, self-tapping (2)8
Not sold separatelyDrill bit, high-speed, 9/64 inch (not shown)9
6
5
2
7
1
3
4
8
is04608
Figure 17. Service Parts, Heated Hand Grip Kit
-J04491 9 / 9