INSTRUCTIONS - Harley
Contents
1. 0289a 4of5 Part No 76364 04 Date 06 04 MOTOR m a Service Parts 2 n i02652 10 6 _ 10 0 19 Description Quantity Part No Description Quantity Part No Bracket indicator 76193 03 Handlebar 56081 82A Boot connector housing 69536 04 Grip handlebar left 56206 96 Headlamp bracket trim Clamp handlebar lower riser right 56542 86A adhesive backed 67834 83 Clamp handlebar lower riser left 56541 86A Bracket antenna 76270 03 Bolt hex head Strap antenna ground 70462 03 1 2 13 x 2 3 4 in long 2 3471 peti te a 10220 03 Lockwasher split 1 2 in 2 7068 Terminal ring 5 16 in 9859 Retainer Wire 70345 84 Brake line assembly front single 45121 96 Adhesive 99839 95 Gasket 0 37 in I D 2 41731 88A Gasket banjo 0 43 in I D 2 41733 88 Items mentioned in text but not in kit Cable strap 5 5 in 140 mm 8 10065 A Original equipment indicator lamps Cable clutch 38661 00 B Riser mounting plate from the Radio Kit Pin anchor 45036 88 Antenna mounting base from the Radio Kit O ring 11179 Original equipment flat washers 1 4 20 screw from the Radio Kit 1 4 20 locknut from the Radio Kit J03277 5 of 52. CM TOR HARLEY DAVIDSON AUA J03277 INSTRUCTIONS REV 06 24 2004 Kit Number 76364 04 INSTALLATION KIT RISER MOUNT RADIO FXDL General This kit is required when installing a Riser Mount Radio Part Number 76360 03 on a 2001 or later FXDL Dyna Low Rider model motorcycle The Riser Mount Radio is available separately at any Harley Davidson dealer This kit is not compatible with internally wired handlebars or some accessories with conflicting mounting requirements See the Service Parts illustration for kit contents CAUTION 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 vehi cle electrical system damage See a Harley Davidson dealer for advice about the amount of current consumed by additional electrical accessories or for necessary wiring changes 00211b AwarninG 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 mod ified Exceeding the maximum amperage can lead to electrical failures which could result in death or serious injury 00310a This radio kit requires up to 1 5 amps additional current from the
3. bracket Ground strap Antenna bracket Antenna mounting surface Figure 4 Antenna Mounting Install the headlamp bracket trim 3 over the indicator lamp opening in the headlamp bracket Complete the installation of the radio and mounting brackets per the instructions in the radio kit Obtain the antenna bracket 4 antenna cable 6 and ground strap 5 from this kit and the antenna mounting base C and antenna from the radio kit See Figure 4 Remove the fasteners holding the right side of the license plate to the license plate bracket 1 Discard the screw and nut but retain the flat washers See the Service Parts illustration Install the antenna bracket 4 and ground strap 5 as shown with the antenna mounting surface toward the rear using the screw E and nut F from the radio kit and the flat washers D saved earlier Crimp the 5 16 inch ring terminal 7 from this kit onto the other end of the ground strap Attach that end of the ground strap to the frame ground under the seat Complete the antenna installation and route the antenna cable per the instructions in the radio kit Mount the radio and complete the installation per the radio kit instructions J03277 Awarnine Harley Davidson Adhesive contains METHYL ETHYL KETONE a chemical known to the State of California to cause cancer or other reproductive harm AWARNING Use Harley Davidson Adhesive in well ventilated areas only Vapors are fla
4. electrical system WARNING Brakes are a critical safety component Contact a Harley Davidson dealer for brake repair or replacement Improperly serviced brakes can adversely affect brake performance which could result in death or serious injury 00054a WARNING The rider s safety depends upon the correct installation of this kit Use the appropriate Service Manual proce dures 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 A Service Manual for your model motorcycle is available from any Harley Davidson dealer Installation WARNING To prevent accidental vehicle start up which could cause death or serious injury disconnect battery cables negative cable first before proceeding 00307a WARNING Disconnect negative battery cable first If positive cable should contact ground with negative cable con nected the resulting sparks can cause a battery explo sion which could result in death or serious injury 00049a 1 Refer to the Service Manual and the instructions for Riser Mount Radio Kit 76360 03 to disconnect the battery cables negative cable first and remove the battery from the vehicle 2 Drain the front brake system See BLEEDING BRAKES in the Service Manual NOTE Cover the front fender a
5. mmable and can be harmful to breath Avoid contact with eyes mucous membranes or pro longed contact with skin Keep out of reach of children 23 Obtain the new left hand handlebar grip 16 and the adhesive 22 from this kit 24 Apply a coat of adhesive to the inside surface of the grip one inch 25 4 mm from the open end Apply a coat of adhesive to the left end of the handlebar 25 Immediately push the grip completely onto the end of the handlebar using a twisting motion Do not hesitate when installing the grip or the adhesive may dry before the installation is complete NOTE At normal room temperature 70 F 21 C allow 6 8 hours to elapse for the adhesive to fully cure 26 Install the left side handlebar switch controls See HAN DLEBAR SWITCHES INSTALLATION in the Service Manual 27 Refer to the THROTTLE CONTROL section of the Service Manual to re install the throttle cables to the original equipment right grip throttle sleeve assembly 28 Install the right side handlebar switch controls See HANDLEBAR SWITCHES INSTALLATION in the Service Manual 29 Install the front brake master cylinder See FRONT BRAKE MASTER CYLINDER in the Service Manual 3 of 5 Awarnine 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 CAUTION Avoid leakage Be sure gaskets banjo bolt s brake line and cali
6. nd the front of the fuel tank with clean shop towels to prevent scratching Damage to the finish could result 3 Remove and discard the brake line that runs from the front brake master cylinder to the front brake caliper See FRONT BRAKE MASTER CYLINDER in the Service Manual CAUTION Do not remove or install the master cylinder assembly without first positioning a 5 32 inch 4mm 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 small section of corrugated cardboard or the eyelet of an ordinary cable strap can be used for this purpose 4 See Figure 1 Squeeze the brake lever and place the insert between the brake lever and lever bracket 1 Brake lever 2 5 32 inch thick insert 3 Brake lever bracket Figure 1 Install Cardboard Insert 1of5 5 Using a T27 TORX drive head remove the front brake master cylinder and clutch lever assemblies refer to CLUTCH CABLE in the Service Manual from the han dlebar 6 Using a T25 TORX drive head remove the switch hous ings and attached wiring from the stock handlebar Refer to HANDLEBAR SWITCHES in the Service Manual Carefully set the switch assemblies on the towel cov ered fuel tank 7 Refer to the THROTTLE CONTROL section of the Service Manual to disconnect the throttle cables from the exis
7. per bore are clean and undamaged before assembly 00321a 30 Obtain the new front brake line assembly 8 and new steel rubber washers 9 and 10 from the kit and install them in place of the original equipment components CAUTION Do not remove or install the master cylinder assembly without first positioning a 5 32 inch 4mm 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 31 See Figure 1 Squeeze the brake lever and remove the insert between the brake lever and lever bracket 32 Fill the brake master cylinder and bleed the brakes See BLEEDING HYDRAULIC BRAKES in the Service Manual 33 Obtain the new clutch cable 12 and anchor pin 13 from this kit and install them in place of the original equipment Refer to CLUTCH CABLE in the Service Manual to re install the clutch lever assembly to the handlebar AwarninG 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 34 Refer to the Service Manual and follow the instructions given to re install the battery and attach the battery cables positive cable first J03277 Safety Check 35 Turn the Ignition Light Key S
8. s 1 In the sequence shown attach the indi cator bracket 6 along with the new riser mounting plate 5 and spacers 4 from the radio kit and the orig inal equipment handlebar upper clamp 3 removed in Step 8 Snug the upper screws but do not fully tighten WARNING Improperly aligned handlebars can contact the fuel tank when turned to the left or right Contact with the fuel tank while riding can cause loss of vehicle control resulting in death or serious injury 15 Slowly turn the front wheel to the full right fork stop and then the full left fork stop to be sure the handlebar does not contact the fuel tank If contact occurs and the han dlebars are properly centered raise the handlebar angle as necessary until proper clearance is obtained 16 Tighten the upper handlebar clamp screws as follows a Tighten the front screws until the upper handlebar clamps make contact with the handlebar riser b Tighten the rear screws to 12 16 ft lbs 16 3 21 7 Nm c Tighten the front screws to 12 16 ft lbs 16 3 21 7 Nm NOTE There will be a slight gap between the upper clamps and the risers toward the rear of the handlebars after tightening i02651 New riser 2 New handlebar Original upper clamp Spacers from radio kit Riser mounting plate from radio kit New indicator bracket Figure 3 Replacement Risers and Handlebar 2of5 i05648 17 18 19 20 21 20 21 22 License plate
9. ting right grip throttle sleeve assembly 8 See Figure 2 Remove the four hex socket head screws 1 retaining the original equipment handlebar upper clamp 2 Save the upper clamp for re installation The screws can be discarded 9 Remove and discard the original handlebar 3 10 Remove and discard the hex head bolts 5 located underneath the upper fork bracket Remove and dis card the stock handlebar risers 4 Save the remaining hardware taking note of the positioning and orientation of each item 11 See Figure 3 and the Service Parts illustration Align the new risers 17 and 18 from the kit the saved cup washers bushings and spacers and the ground wire on the right side only Secure with two new hex head bolts 19 and lockwashers 20 from the kit Tighten to 50 60 ft lbs 68 81 Nm 12 Remove the indicator lamps A from the headlamp bracket See INDICATOR LAMPS in the Service Manual i02650 Clamp screw 4 Upper clamp Handlebar Handlebar riser Hex head bolts 2 Figure 2 Removing the Original Equipment Handlebar J03277 13 Install the rubber boot 2 from this kit over the original equipment indicator lamp housing Install the indicator lamp assembly into the indicator bracket 1 from this kit NOTE To make sure that the handlebar is centered verify that the knurled areas on the outboard side of each riser are equal 14 See Figure 3 Place the new handlebar 2 onto the han dlebar riser
10. witch to IGNITION and test each handlebar switch for proper operation 36 Turn the handlebar to the left and right steering stops testing the handlebar control functions at each stop WARNING Wires and cables must not pull tight when handlebars are turned fully to left or right fork stops Be sure wires and cables are clear of fork stops at steering head so they will not be pinched when fork is turned against stops Steering must be smooth and free with no binding or interference Interference with steering could result in loss of vehicle control and death or serious injury 37 Apply the front brake hand lever to test operation of the brake lamp 38 Refer to the Service Manual and follow instructions to install the seat WARNING After installing seat pull upward on front of seat to be sure it is in locked position While riding a loose seat can shift causing loss of control which could result in death or serious injury 00070a WARNING Prior to starting engine verify that the throttle control will snap back to the idle position when released A throttle control that prevents the engine from automati cally returning to idle can lead to a loss of control which could result in death or serious injury WARNING After servicing 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 0
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