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REV. 2007-08-17
ROCKER DRAG HANDLEBAR KIT
GENERAL
INSTALLATION
Kit Number
Preparation
56947-08
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harleydavidson.com (English only).
To prevent accidental vehicle start-up, which could cause
death or serious injury, disconnect battery cables (negative
(-) cable first) before proceeding. (00307a)
Additional Parts or Accessories Required
Separate purchase of additional parts or accessories is
required for proper installation of this Handlebar Kit on your
model motorcycle. Please see the P&A Retail Catalog or the
Parts and Accessories section of www.harley-davidson.com
(English only) for a list of required parts or accessories for your
model.
Fresh, uncontaminated brake fluid will be needed for the proper
installation of this kit. Refer to your Owner's Manual or the
Service Manual for this year and model motorcycle to determine
the correct brake fluid for this vehicle.
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)
1.
Refer to the Service Manual and follow the instructions
given to remove the seat and disconnect the battery
cables, negative cable first. Retain all seat mounting
hardware.
2.
Remove the console. Refer to INSTRUMENT CONSOLE
(FXCW/FXCWC), REMOVAL in the Service Manual.
Two cable straps (Part Number 10006, not included in the kit)
should be used to replace the straps removed and discarded
during removal of the original handlebar.
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.
Please refer to the P&A Retail Catalog or the Parts and
Accessories section of www.harley-davidson.com (English
only) to see the selection of Genuine Motor Accessory hand
grips that are available.
The help of an assistant will ease the assembly of the handlebars to the riser.
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. (00330a)
3.
Remove the fuel tank. Refer to FUEL TANK REMOVAL
in the Service Manual.
4.
Bleed the brake fluid from the front brake. See BLEEDING
BRAKES in the Service Manual.
Original Handlebar Removal
NOTE
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. (00333a)
NOTE
Cover the front fender 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. (00320a)
1.
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.
2.
Remove the old brake line from the motorcycle.
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 5 and Table 1.
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3.
Refer to CLUTCH HAND CONTROL: REMOVAL in the
Service Manual, and follow the instructions to disconnect
the clutch cable from the clutch lever.
Disconnect the idle and throttle cables from the induction
module. Refer to INDUCTION MODULE: REMOVAL in
the Service Manual.
Disconnect the clutch cable from the side cover, and
remove the cable from the vehicle.
If not being replaced, remove the right grip/throttle sleeve
and set it aside for installation to the new handlebar.
NOTE
Before disconnecting the handlebar control wiring, note the
wire routing.
12. Refer to HANDLEBAR SWITCHES: LEFT HANDLEBAR
CONTROLS in the Service Manual for removal of the leftside switch housing assembly and wire harness.
4.
13. See Figure 1. Remove and retain the four hex socket head
screws (1) that fasten the handlebar upper clamp (2) to
the riser (3). Remove and retain the clamp. Remove the
handlebars (4 and 5) from the motorcycle.
Remove and discard the cable straps retaining the handlebar control, turn signal and headlamp wiring on either
side of the steering head.
Disconnect the handlebar control wiring from the gray
eight-way and black six-way main harness connectors
under the fuel tank. Refer to the MOLEX ELECTRICAL
CONNECTORS section of the Service Manual for disconnection procedures.
14. 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, if not being replaced.
NOTE
Before disconnecting the turn signal wiring, note the turn signal
wire routing.
5.
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4
Separate the 6-way turn signal connector halves.
1
NOTES
DO NOT remove the wires from the handlebar switch connector
pin housings under the fuel tank.
2
5
DO NOT remove the wires from the Multilock connector pin
housing under the fuel tank.
6.
Note the wire colors and positions in each cavity of the
socket housings leading from the switches. Refer to the
wiring diagram and the MOLEX ELECTRICAL CONNECTORS section in the Service Manual. Remove the wires
from the socket housings.
3
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.
7.
Use tape to wrap the wire terminal ends from each individual harness to make separate leaders. Wrap each
leader tight enough to enter the grommet hole and pass
easily through the new handlebars.
8.
Using a T-27 TORX® drive head, remove the front-brake
master cylinder and clutch-lever assemblies from the
handlebar, along with the attached turn signal lamps and
mirrors.
9.
Pull the wire sheath and enclosed harnesses through the
handlebars to free the handlebar controls and turn signal
lamps from the motorcycle.
1.
2.
3.
4.
5.
Figure 1. Handlebar Clamp and Riser
New Handlebar Wiring
NOTE
The right- and left- side handlebars can be identified by the
"R" or "L" stamped near the grip end underneath the Bar &
Shield logo.
1.
See Figure 5. Obtain the right-side handlebar (1) and one
grommet (3) from the kit
2.
Slide the grommet onto the right-side switch and turnsignal wire bundle, positioning the grommet close to the
switch end.
3.
Apply a light coat of liquid soap, window cleaner, or allpurpose lubricant such as WD-40® to the wire bundle.
Set the handlebar control/turn signal lamp assemblies
aside.
10. 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.
Clamp screw (4)
Handlebar upper clamp
Handlebar riser (reference)
Right-side handlebar
Left-side handlebar
11. Refer to the THROTTLE CONTROL section of the Service
Manual to disconnect the idle and throttle cables from the
right grip/throttle sleeve assembly.
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11. 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.
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New Handlebar Installation
NOTE
The help of an assistant will ease the assembly of the handlebars to the riser (Steps 1 through 4, below).
3
3
Do not remove plastic plug from handle bar, which protects
the internal electrical wires from sharp edges. Removal of
the plug can result in damage to the wires, causing a short
circuit which could result in death or serious injury.
(00569b)
1.
2
1. Upper switch housing screw
2. Lower switch housing screw
3. Pinch points
Obtain the new left- and right-side handlebars, and position them, as far inward as they will go, onto the riser (see
Figure 3, 4). Route the wire bundles down through the
large oval opening in the upper fork bracket (triple tree).
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2
Figure 2. Switch-Housing Wire Routing (Right-Side
Housing Shown)
6
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. (00415b)
4.
3
4
5
See Figure 2. Route the switch wire bundle through the
switch housing as shown. Gently feed the wire bundle into
the oblong switch wire hole near the outer end of the new
right-side handlebar, and toward the inner (flared) end of
the bar.
5.
Pull the taped end of the wire bundle out through the flared
bar end.
6.
Repeat Steps 1 through 5 for the left-side handlebar and
wire bundle.
1. Right-side handlebar
2. Alignment dots (2) visible in gap between riser
and clamp
3. Handlebar riser
4. Position handlebar on riser as far inward as it
will go
5. Wire notch in riser
6. Handlebar upper clamp
Figure 3. Proper Positioning of Handlebar in Riser
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. (00416d)
7.
See Figure 5. Insert the switch-wire grommets (3) into
place in the switch-wire holes in the handlebars.
8.
Loosely fasten the front-brake master cylinder and clutchlever assemblies to the new handlebars with the clamps
and screws removed earlier.
9.
Loosely fasten the handlebar switch housings to the new
handlebars.
10. Remove the tape from the ends of the wire bundles.
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2.
See Figure 1. Obtain the handlebar upper clamp (2) and
four hex socket head screws (1) removed earlier. Position
the upper clamp over the handlebars, and fit the wire
bundles into the notch (see Figure 3, 5) in the center of
the riser.
Install the upper clamp with the clamp screws. Snug the
upper screws enough to hold the handlebars loosely in
place.
NOTE
When rotating the handlebars, be careful that the riser or clamp
does not scratch the finish of the handlebars. LOOSEN THE
UPPER CLAMP SCREWS before rotating the handlebars to
prevent scratching of the handlebar finish. Scratches in the
finish of the handlebars can lead to corrosion of this area.
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3.
Loosen the upper clamp screws if necessary, and carefully
rotate the handlebars in the riser so the two alignment
dots are visible through the gap between the rear of the
riser and the rear of the clamp (see Figure 3, 2).
NOTE
Make sure the flared ends of the bars remain as far inward as
they will go in the riser cavities.
4.
Snug all four screws enough to hold the handlebars firmly
in place, but do not fully tighten.
5.
Follow the routing noted in the disassembly steps (left
switch wire bundle to left side of frame; right switch wire
bundle to right side of frame) until the wires reach the
switch-wire pin housings.
6.
Refer to the notes made during the removal steps, and
the wiring diagram and MOLEX ELECTRICAL CONNECTORS 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.
7.
8.
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.
13. Slowly turn the front wheel to the full right fork stop and
then the full left fork stop to be sure the handlebars do not
contact the fuel tank.
NOTE
When rotating the handlebars, be careful that the riser or clamp
does not scratch the finish of the handlebars. LOOSEN THE
CLAMP SCREWS before rotating the handlebars to prevent
scratching of the handlebar finish. Scratches in the finish of
the handlebars can lead to corrosion of this area.
14. If contact occurs and the handlebars are properly bottomed
in the riser, loosen the clamp screws, and CAREFULLY
rotate the handlebar angle upward only as necessary until
proper clearance is attained.
15. Tighten the handlebar clamp screws as follows (see Figure
4:
a.
Tighten first the left front screw, then the right front
screw to 12-16 ft-lbs (16.3-21.7 Nm).
b.
Tighten the right rear screw, then the left rear screw
to 12-16 ft-lbs (16.3-21.7 Nm).
c.
Tighten the left front screw, then the right front
screw to 12-16 ft-lbs (16.3-21.7 Nm).
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1
2
4
6
3
9.
Follow the turn signal harness routing noted earlier to the
6-way turn signal pin housing under the right side of the
fuel tank.
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.
10. Obtain two cable straps (Part Number 10006, sold separately). Use one strap to fasten the left-side turn signal
harness to the right-side switch wire harness on the right
side of the steering head.
Use the second strap to fasten the headlamp harness to
the left-side switch wire harness on the left side of the
steering head.
Figure 4. Handlebar Clamp Screw Tightening Sequence
Failure to tighten hardware to the specified torque could
result in damage to the installed accessory. (00508b)
11. Connect the 6-way AMP socket housing to the main harness pin housing under the fuel tank.
NOTE
There will be slight gaps between the upper clamp and the
riser toward both the front and rear of the handlebars after
tightening. DO NOT OVER-TIGHTEN in an attempt to minimize
or eliminate these gaps.
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. (00330a)
16. Refer to RIGHT HANDLEBAR SWITCH: INSTALLATION
and THROTTLE CONTROL: ASSEMBLY/INSTALLATION
in the Service Manual, and follow the instructions given
to install the throttle control cables and a new (purchased
separately) or original right grip/throttle sleeve assembly.
Follow the CABLE ROUTING instructions for your model.
Install any clips or wire guides saved in disassembly.
12. Re-install the fuel tank. Refer to FUEL TANK-INSTALLATION in the Service Manual.
Improperly aligned handlebars can contact the fuel tank
when turned to the left or right. Contact with the fuel tank
can cause cosmetic damage. (00372a)
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See INDUCTION MODULE: INSTALLATION in the Service
Manual to install the cables to the throttle wheel. Refer to
THROTTLE CABLES for cable lubrication and adjustment.
17. Adjust the position of the switch housing and the brake
lever assembly on the handlebar for rider comfort and
posture. The brake master cylinder must be horizontally
level.
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NOTE
Tighten the top brake lever clamp screw before tightening the
bottom screw.
length of the cable. This shield must be cut into two approximately equal sections and positioned to protect the cable at
the handlebar riser and upper front fork.
18. Use a T-27 TORX drive head to tighten first the top, then
the bottom brake-lever clamp screws to 71-80 in-lbs (8.09.0 Nm).
When cutting the shield, be careful not to damage the clear
coating of the braided cable.
NOTE
Tighten the lower switch housing screw before tightening the
upper screw. This will leave any gap in the switch housing at
the front for best appearance.
19. Use a T-25 TORX drive head to tighten first the lower,
then the upper switch housing screws to 35-45 in-lbs
(4.0-5.1 Nm).
3.
Carefully inspect the new clutch cable (sold separately)
for damage or defects, and replace if damaged. Install per
the CLUTCH HAND CONTROL instructions in the Service
Manual.
SAFETY CHECK
20. Verify that the right grip/throttle sleeve rotates and returns
freely and does not bind on the handlebar or switch
housing.
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. (00371a)
NOTE
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.
•
21. 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 LEFT HAND GRIP,
INSTALLATION instructions in the Service Manual.
22. Refer to LEFT HANDLEBAR SWITCH: INSTALLATION
in the Service Manual. Adjust the positions of the switch
housing and the clutch lever assembly on the handlebar
for rider comfort and posture.
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)
1.
FINAL ASSEMBLY
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. (00318a)
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)
1.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
2.
Turn the Ignition/Light Key Switch to IGNITION, but do
not start the motorcycle. Test each handlebar switch for
proper operation.
3.
Turn the handlebar to the left and right steering stops,
testing the handlebar control functions and turn signal
operation at each stop.
4.
Apply the front brake hand lever to test operation of the
brake lamp.
5.
Refer to the Service Manual, and follow instructions to
install the seat.
Carefully inspect the new braided brake line (sold separately) for damage or defects, and replace if damaged.
Install per the instructions included with the brake line.
Use the larger P-clamp and the screw that comes with the
brake line to fasten the braided line to the bottom of the
fork stem.
2.
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).
23. Use a T-27 TORX drive head to tighten first the top, then
the bottom clutch-lever clamp screws to 71-80 in-lbs (8.09.0 Nm).
24. Use a T-25 TORX drive head to tighten first the lower,
then the upper switch housing screws to 35-45 in-lbs
(4.0-5.1 Nm).
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.
Bleed the brakes. See BLEEDING HYDRAULIC BRAKES
in the Service Manual.
NOTES
The new braided clutch cable has a short piece of looselyinstalled clear plastic shield that can be positioned along the
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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)
6.
Adjust the mirrors for proper field of vision and compliance
with local regulations. Adjust the front turn signals to point
straight ahead for proper visibility. Tighten the hex nuts to
60-96 in-lbs (6.8-10.9 Nm).
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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. (00390a)
Do not remove plastic plug from handle bar, which protects
the internal electrical wires from sharp edges. Removal of
the plug can result in damage to the wires, causing a short
circuit which could result in death or serious injury.
(00569b)
7.
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. (00289a)
If the plug SHOULD happen to come out, it MUST be
replaced. See the Service Parts list.
SERVICE PARTS
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1
3
C
4
B
2
4
A
3
Figure 5. Service Parts, FXCW/FXCWC Drag Handlebar
Table 1. Service Parts Table
Item
Description (Quantity)
Part Number
1
Handlebar (right side)
Not sold separately
2
Handlebar (left side)
Not sold separately
3
Handlebar grommet (2)
11386
4
Hole plug (2)
11654
Items mentioned in text, but not included in kit:
A
Original equipment (O.E.) handlebar riser
B
O.E. handlebar clamp
C
O.E. handlebar clamp screw (4)
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