-J04258 REV.

2007-05-18

HANDLEBAR GRIPS
GENERAL 3. Remove the end cap from the existing left handlebar grip
if so equipped.
Kit Numbers With "glueless" grip: Remove the grip from the han-
56246-08, 56257-08, 56263-08, 56275-08, 56425-08, dlebar.
56459-08, 56518-08, 56729-08, 56740-08, 57202-08 With glued grip: Remove the grip by carefully cutting it
away from the handlebar using a sharp blade or knife.
Models
For model fitment information, please see the P&A Retail Cat-
alog or the Parts and Accessories section of www.harley-
davidson.com (English only). Do not lubricate left handlebar grip before installation.
Lubricating grip can cause it to come off while riding,
Kit Contents which could result in loss of control and death or serious
See Figure 4 and the Service Parts Tables. injury. (00315a)

INSTALLATION NOTE
Make sure that the handlebar surface is smooth, dry and thor-
Remove and Install the Left-Side Grip oughly cleaned of all dirt or adhesive residue.
1. See Figure 1. Using a T-25 TORX® drive head, remove Make sure that the inside of the new grip is clean and dry.
the upper and lower switch housing screws (1).
4. Position the new left grip (4) so the larger diameter portion
of the flange (5) is at the bottom. Push the grip fully onto
is01283
the handlebar.
1
5. Position the lower switch housing beneath the grip so that
the grooves (2) on the outboard side of the switch housing
2 fit over the flange on the end of the grip.
6. Position the upper switch housing over the handlebar and
lower switch housing.
7. Start the upper and lower switch housing screws, but do
not tighten. Verify that the wire harness conduit runs in
the depression at the bottom of the handlebar.

3 8. Position the clutch hand lever assembly inboard of the

5 switch housing assembly, engaging the tab on the lower
switch housing in the groove at the bottom of the clutch
4 lever bracket.
2 9. Align the hole in the handlebar clamp with the hole in the
clutch lever bracket, and start the lower screw with flat
1 washer. Adjust the switch housing and clutch hand control
position for rider comfort.
1. Switch housing screws 10. Using a T-27 TORX drive head, tighten first the upper,
2. Grooves then the lower handlebar clamp screws to 60-80 in-lbs
3. Handlebar clamp (6.8-9 Nm).
4. Left handlebar grip
5. Larger diameter of flange 11. Using a T-25 TORX drive head, tighten first the lower,
then the upper switch housing screws to 35-45 in-lbs (4-
Figure 1. Left Handlebar Switch Housing 5.4 Nm).

2. Using a T-27 TORX drive head, loosen the upper screw

securing the handlebar clamp (3) to the clutch lever
bracket. Remove the lower clamp screw with flat washer.
Loosen the clamp and position the clutch hand lever
assembly away from the switch housing.
Separate the upper and lower switch housings.

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Remove and Install the Right-Side Grip
Do not remove or install the master cylinder assembly
without first positioning a 5/32-inch (4 mm) thick insert
between the brake lever and lever bracket. Removing or
installing the master cylinder assembly without the insert
in place may result in damage to the rubber boot and
plunger on the front stoplight switch. (00324a)
NOTE
A section of corrugated cardboard or the eyelet of an ordinary
cable strap can be used for this purpose. See Figure 2.
is04504
3 1
1 3
1. 5/32-inch (4 mm) thick insert
2. Brake lever
3. Brake lever bracket
Figure 2. Protect Stop Light Switch
1. Place a 5/32-inch (4 mm) thick insert between the brake
lever and the lever bracket.
2. Using a T-25 TORX® drive head, remove the upper and
lower switch housing screws.
3. Using a T-27 TORX drive head, loosen the upper screw
securing the handlebar clamp to the brake master cylinder
housing. Remove the lower clamp screw with flat washer.
Loosen the clamp and position the master cylinder
assembly away from the switch housing.
Separate the upper and lower switch housings.
4. Remove the end cap from the existing right handlebar grip
if so equipped.
Remove the grip from the handlebar.
NOTES
The twist grip sensor in the right side of the handlebar has a
seal cap that protects internal electrodes from dirt and moisture,
and also serves as a retention device for the throttle grip.
To remove the grip, a slight tug may be necessary to release
the index pins in the grip from the receptacle in the seal cap.
Upon removing the grip, verify that the seal cap is installed at
the end of the twist grip sensor. If the seal cap is not present,
proceed as follows:
• See if the seal cap is still fastened to the index pins inside
the old throttle grip. If so, use a stiff piece of mechanics'
wire to lasso the seal cap and pull it free of the index pins.
-J04258
Obtain a new seal cap if the old cap is damaged or
missing.
• Check the condition of the O-ring on the seal cap. Install
a new O-ring if necessary.
• Install the seal cap engaging the legs in the slots at the
end of the twist grip sensor. For best results, install one
leg first. Depressing the second leg slightly with a small
flat blade screwdriver, push down on the seal cap until
fully installed. See Figure 3.
Make sure that the handlebar surface and the inside of the
new grip are smooth, dry and thoroughly cleaned of all dirt.
If the handlebar grips are patterned, align the pattern on the
right grip with the pattern on the left grip while the throttle is in
the fully closed position.
is04612
2
1. Handlebar
2. Throttle twist grip sensor
3. Seal cap
Figure 3. Re-install Seal Cap if Removed
5. Slide the new throttle grip over the end of the handlebar.
Rotate the grip to verify that the internal splines are
engaged with those on the twist grip sensor.
6. Refer to Figure 1, which shows the similar left-side switch
mounting. Position the lower switch housing beneath the
grip so that the grooves (2) on the outboard side of the
switch housing fit over the flange on the end of the grip.
7. Position the upper switch housing over the handlebar and
lower switch housing.
8. Start the upper and lower switch housing screws, but do
not tighten. Verify that the wire harness conduit runs in
the depression at the bottom of the handlebar.
9. Position the brake master cylinder housing inboard of the
switch housing assembly, engaging the tab on the lower
switch housing in the groove at the bottom of the master
cylinder housing.
10. Align the hole in the handlebar clamp with the hole in the
master cylinder housing, and start the lower screw with
flat washer. Adjust the switch housing and brake hand
control position for rider comfort.
11. Using a T-27 TORX drive head, tighten first the upper,
then the lower handlebar clamp screws to 60-80 in-lbs
(6.8-9 Nm).
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12. Using a T-25 TORX drive head, tighten first the lower, NOTE
then the upper switch housing screws to 35-45 in-lbs (4- Do not pull the switch housing so far inboard as to cause the
5.4 Nm). throttle grip to bind or drag on the handlebar. Actuate the
throttle grip to verify that it freely returns to the idle position.
13. Verify that the right grip/throttle sleeve rotates and returns
freely and does not bind on the handlebar or switch
Before starting engine, be sure throttle control will snap
housing.
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)

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SERVICE PARTS
Table 5. Service Parts, Kit 56425-08
is00740 - Aileron -
3 Item Description (Quantity) Part Number
2
1 Right grip/throttle sleeve 56233-08
2 Left grip 56231-03

1
3 Table 6. Service Parts, Kit 56459-08

Figure 4. Service Parts: Handlebar Grips - Contoured Chrome/Rubber -

Item Description (Quantity) Part Number
NOTES 1 Right grip/throttle sleeve (with end cap) 56461-08
For illustration purposes, generic styled handlebar grips are 2 Left grip (with end cap) 56460-01A
shown. 3 End cap (2) 56480-01
Each grip includes a replaceable end cap, except for Nostalgic
and Aileron grips which have closed ends.
Grips and replaceable end caps are also available separately.
Table 7. Service Parts, Kit 56518-08
See the tables that follow.
- Flame -
Table 1. Service Parts, Kit 56246-08 Item Description (Quantity) Part Number
1 Right grip/throttle sleeve (with end cap) 56527-08
- Chrome/Rubber (Small Diameter) -
Item Description (Quantity) Part Number 2 Left grip (with end cap) 56519-02
1 Right grip/throttle sleeve (with end cap) 56245-08 3 End cap (2) 56656-02
2 Left grip (with end cap) 56247-96A
3 End cap (2) 56252-96
Table 8. Service Parts, Kit 56729-08

- Stealth -
Table 2. Service Parts, Kit 56257-08 Item Description (Quantity) Part Number
1 Right grip/throttle sleeve (with end cap) 56201-08
- Tribal, 1.5 inch (38 mm) Diameter -
Item Description (Quantity) Part Number 2 Left grip (with end cap) 56202-04
1 Right grip/throttle sleeve (with end cap) 56265-08 3 End cap (2) 56480-01
2 Left grip (with end cap) 56732-08
3 End cap (2) 56748-08
Table 9. Service Parts, Kit 56740-08

- Skull, 1.5 Inch (38 mm) Diameter -

Table 3. Service Parts, Kit 56263-08 Item Description (Quantity) Part Number
1 Right grip/throttle sleeve (with end cap) 56738-08
- Chrome/Rubber (Large Diameter) -
Item Description (Quantity) Part Number 2 Left grip (with end cap) 56736-04
1 Right grip/throttle sleeve (with end cap) 56262-08 3 End cap (2) 56754-04
2 Left grip (with end cap) 56264-96A
3 End cap (2) 56252-96
Table 10. Service Parts, Kit 57202-08

- Ironside -
Table 4. Service Parts, Kit 56275-08 Item Description (Quantity) Part Number
1 Right grip/throttle sleeve (with end cap) 56926-08
- Nostalgic -
Item Description (Quantity) Part Number 2 Left grip (with end cap) 56971-07
1 Right grip/throttle sleeve 56280-08 3 End cap (2) 56480-01
2 Left grip 56278-96A

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