Indian Motorcycle 2879586 User manual

TOURPULLBACK HANDLEBARKIT
KIT P/N 28?9586
Application
AII MYl4 TourMotorcycles
NOTE: Before you begin, read theseinstructions and check to be sureallparts and t
accounted for in package.Please retain theseinstallation instructionsfor futurerefere
parts ordering information. Foryour safety,and to ensure a satisfactoryinstallation,
pe
installation steps correctly in the seguence shownbeiow.
KitContents:
Quantity
I
2
I
Part
Description
Tour Pullback Handlebar
Nylon Straps
Instructions
PartNumber
1019569
708i504
992436s
#2 Phillips Screwdriver
4 mm Hex KeySocket
8mm Hex KeySocket
19mm socket
Ratchet
Torqr:eWrench
SideCutters
Digital Camera (Optional)
Youwill need to supply:
# I Phillips Screwdriver
#T25Torx Bit
5 mm Hex Key Socket
I0 mm socket
Dental Pick
Exterrsion
Protective Cloth
BenchVise (Optional)
Electrical Tape (Optiona1)
APPROXIMATE ASSEMBLYTIME: 90minutes
-t-
Tour Pullback
Handlebar

NOTE: protect all finished surfacesduring
theseoperations.
l. Remo" crews from
thetopofthe
headlifht bezer.
Remove
bezel
by firmly putting th"i"t t;rtion away
firsr.
The
bezer
will disc"**"ifrom three
rubber
g'rommets.
See
Figrure
l.
2.With a l0 mm socket,remove three M6 hex
screws,
washer and aluminum spacer" n.flr'a
the headlight assembly frame.See
Figrure
2.
TIP: Remove aluminum spacers ind.ividually
asthey are not attached headlight assembly.
See
Figrure
2.
MG Flange
Head Screw
Figure I
i_\_
Figure Z
Headlight
Assembly
\\ MG Flange
Screw
w
f-
Washer
'a-.\a
"'a
-2-

3. Removethe sealing boot. Pressthe looped
end of the wire bulb retainer clip and swing
the end toward the center of the bulb to
releaseit from the latch tab.
With the wire
connector attached,puII the bulb out and
protect. Do not disconnect thewire harness.
NOTE: Avoid touching a halogen lamp with
bare fingers. Oil from your skin leaves a
residue, causing ahot spot thatwill shorten
the life of the lamp. If alamp is touched,clean
it thoroughly with denatured alcohol.
4. Loosenfront M6 button head screw two turns
and remove rear MO
button head screw from
the fuel tank console. Slide forvvard on tank,
Iift and relocate console to side of fuel tank.
Existing console wire terminals or leather
strapdo not need to be disconnected"
SeeFigrure3.
MG Button
Head Screws
figure 3
\ t"t't/'
-\ ,-/ ,/
.----- --=r'
5.Trace the wiring exiting the center of the handlebars and cut the two nyion straps restraining
the handlebar wiring with side-cutters. Take care to not cut any wires. SeeFigure 8 for reference.
TIP: Take photos of the wire routing from a front view and arear view for reference during
re-assembly.
6. To make certain wiring is plugged into the correct terminal during re-assembly, ensure the
wiring is Iabeled on both ends of each terminal. There are a total of seven terminals coming
from the handlebars (four right hand / three left Lnnd).
NOTE: teft and right hand wiring have identical terminals and should be labeled accordingly.
Mark terminals as a matched pair if ]abels are missing from the vehicle.
7. With a dental pick depress lock tab and disconnect all wire terminals that trace into the
handlebars and pull wires through rubber grommets.
8. On the bottom side of the clutch mount, remove two # I Phillips screws and remove cover,Using
a dental pick, discormecl clutch wiring terminal.
9. Remove the two M6 screws from the clutch clamp and remove clutch lever assembly. Carefirlly
hang clutch lever assembiy from cable so excessive bending or kinking does not occur to the
cable.
10.Remove the two M6 screws from the brake master cylinder clamp and assembly. Support
master cylinder level on a flat and horizontal surface.
WARNING: Failure to continuously support masler cylinder in a level orientation may
cause reduced braking perforrnance or braking failure.
-3-

Handlebar Removal and Disassembly (retain all
fasteners.covers.clamps for re-assembly):
I I.With a 19mm socket,removethe twoMI2
hex screwsfrom under the handlebar risers.
Ensurerubber inserts retained by the
Ml2 bolts do not fali out.SeeFignrre
4.
i Triple Clamp
Rubber
Inserts
IVItzHex Bolt
12.CarefuIly slide the handlebar and riser assembly out of triple clamp frame. SeeFigure 4.
13. Remove the front two and rear two M8 cap screws from the handlebar riser cap and remove
cap and risers from the handlebar.
TIP: Using protective cloth, lightly clamp handlebars in vise for ease of assembly and
disassembiy.
14.Using your thumb, deflect the rubber flange of the left hand grip next to the switch housingrto
reveal the #2 Phillips head screw. Remove screw and slide grip off of handlebar.
15.Using the T25Torx bit, remove the tlree Torx fasteners from the backside of the switch housing.
16.Using the T25Torx bit, remove the four Torx fasteners from the backside of the right hand
switch housing. Split switch housing apart and slide the right hand grip off of handlebar. Set
grip aside in a clean location.
I7. From the switch housing wiring slots in the handlebar, puli the left and right hand wiring
harnesses and switch housingrsfrom the handlebar.
TIP: Feed the excess wire into the center slot of the handlebar while simultaneously pulling
from the switch housing end.
Accessory Handlebar Installation (use retained fasteners. covers. clamps for re-assembly where
aprclicable):
18.Insert the right hand suritchhousing wiring harness into the right hand switch housing wiring
slot in the handlebar and pull aII terminals out of the center wiring slot in the handlebar. PuiI
harness taught untii switch housing is located adjacent to the wiring siot.Repeat for the left
hand switch housing wiring.
TIP: Use a small piece of electrical tape to hold the wire terminals togTetherassistin sliding
wires througthhandlebars.
19.Remove any dust, dirt or grime from the right hand grip tube, throttle switch housing assembly,
and the handlebar prior to reassembly.
20.Slide the right hand grip onto the handlebar.
2l,Assemble switch housing so the single boss on the rider-faced switch housing is located in the
5.4 mm hole on the handlebar and so the throttle components are aligned.
-4-

22.Install the retained four Torx fasteners into the backside of the switch housing and torque to
3I +/- 4.5in.lb (3.5
+/- 0.5Nm).
NOTE r Excessive force is not required to install these components. Ensure components are
aligned and that wires are inside of the switch housing prior to closing switch housing halves.
CAUTION: Check the throtlle operation. Open throtfle fully and then release the grrip.
Throttle grip rnurt leturn freely and completely to the idle position. If throtfle return i3
sluggish or if it does not retutn freely anrd completely, disasaemble throttle aide switch
housing to deterrnine the cause. Do not operate the vehicle until throtfle operales freely,
23.Assemble left hand svitch housinq so the single boss on the rider-faced switch housing is
located in the 5.4 mm hole in the handlebar. Route the clutch wire through the provided slot in
sritch housing. Install the three retained Torx fasteners into the backside of the switch housing
and torque to 3I +/- 4.5in.Ib (3.5
+,r-
0.5Nm).
NOTE: Excessive force is not required to install these components.With the exception of
the clutch wire terminal, ensure wires are inside of the switch housing prior to closing switch
housing halves.
24.Remove handlebars from vice.
25.Install risers and riser cap onto the handlebar
by centering the handlebar knurling to the
riser cap.Rotate
the cap sothebottom edge
of the riser cap slot and the top edge of the
center handlebar slot are 2 mm apart. See
Figure 5.
26.Loosely install two front and two rear MB cap
screws.Torgue the front riser two M8 cap
screws
to l8 +/- 2ft.lb (24.4
+/- 2.7Nm).
Do
not torgue the rear cap screws at this time.
27.hstall the handlebar onto vehicle and replace two MI2 bolts with washers.Torgue to 60 +/-
6 ft.lb (81.3+/- 8.1 Nm). Route handlebar wiring towards front of fairing.
28.While holding the brake master cylinder level, install onto vehicle with two M6 screws and
clamp adjacent to the riqht hand *ritch housing. Ensure features on ciamp match like features
of master ryIinder. Position to rider preference. $tarting with the top screw and lorgue both
fastenersto70 +/- I0 in.Ib (7.9+/- I.l Nm).
29.Install clutch lever assembly onto vehicle with two M6 screws and clamp adjacent to the left
hand switch housing. Position to rider preference. Ensure the features on the clamp match like
features of the clutch mount. Starting with the top screw tolque both fasteners io 70 +/-
I0 in.lb (7.9+/- I.l Nm).
30.Cormect clutch wire terminals and replace cover and two # I Phillips screws and tiqhten
securely,
3i. Slide the left hand gtip onto the handlebar and fasten with the retained #2 Phillips head screw
and tighten secureiy.
-5-
Handlebar
Figure 5 Center Slot

32.Considering the switch housings, grips and levers, position the handlebars to rider preference
such that there is adequate clearance to the fuel tark when turning left to right. Torque the
lower riser two M8 cap screws to LA
+/- 2 ft.Ib (24.4+/- 2.7 Nm).
Front Bodywork Re-assembly:
33.
Routeleft hand handlebar wiring to left
side of fairing and place the two harnesses
through the left hand side rubber grommet
in the fairing frame. Route the right hand
handlebar wiring to the right side of the
fairing and harnesses through the right hand
side nrbber grommet in the fairing frame.
Ensuring correct label pairing, connect the
handlebar wiring terminals. SeeFigures
6 and 7 detailing the harnesses through
grommets.
34.Install the new nylon strapsinto the two
push dart locations in fairing locations near
the rubber grrommets. Neatly restrain the
handlebar wiring by using the available
nylon straps.Cinch tight and remove excess
nylon strapping with side cutters,careful
not to damage any wires. SeeFigure 8 for
reference wire routing and strap locations.
TIP: Usephoto from Step5 to aid in wire
routing and nylon strap locations.
35.Turn handlebar left and right, Iock-to-1ock,
and determine if there is any resistancefrom
wire binding. If you feel resistanceor see
wire interference, determine the causeand
re-bundle wires asnecessary.
36.InstaII the new bulb and secure the retainer.
Reinstallthe sealing boot. Make sureit seals
tightty around the bulb base and lens to
prevent condensation.
NOTE: Avoid touching ahalogen lamp with
bare fingers. Oil from your skin leaves a
residue,causing ahot spot thatwill shorten
the life of the lamp. If alamp is touched,clean
it thoroughly with denatured alcohol.
Grommet
Harnesses
-6-

37.Install the headlight assembly into the fairing by installing the three aluminum spacers,
headlight assembly, three washers then three M6 hex screws.Torque to 84 +/- 6 in.Ib
(9.4+/- 0.6Nm).
TIP: Insert the hex screw and washer into the top mountingrhole of the headlight assembly.
Install an aluminum spacer onto the top hole and loosely install screw into fairingt.This will
allow placement of the other two aluminum spacers prior to installing the remaining M6
washers and screws.
38.Insert the headlight bezel by inserting bezel features into the rubber grommets in the fairing.
Install the retained two MOflange screws and torque to 36 +/- 6 in.Ib (4.0 +/- 0.6Nm).
Clutch Freeplay Adjustment:
39.Adjust clutch freeplay before vehicle operation by referring to Clutch Freeplay Adjustment
under the maintenance section of the Owner's Manual.
P/N 9924363
Rev 02 06/13 -7-