Extended Cable/Line Kit 2012-later FXD (non-ABS)
Contents
1. m As with any repair or modification involving the wiring system first disconnect the battery m Starting with the control harness extension kit 9 wire kit 4 into 1 plug 5 into 2 plugs there should be a large diameter 3 8 heat shrink tube over each of the two harness if not slide one of the supplied larger diameter heat shrink tubes onto each of the harness and up towards the connectors to give room to solder m Then cut the supplied smaller diameter 1 8 heat shrink tubing into 9 equal pieces and prepare each harness extension for soldering by first sliding one of the small diameter heat shrink tube pieces over each of the wire ends and sliding them out of your way for now m Strip and prepare the ends of each wire coming out of the left and right control harnesses note there will be four on the left and four plus one more on the right a white wire with a thin black stripe that is NOT twisted together with the white red wire While preparing the wires for soldering try to stagger the lengths slightly this makes it easier to slide the large heat shrink tubing back over the soldered connections and ultimately easier to install into the handlebars m Match up the wire colors on each side with the extension wires in the kit and solder them to their mates figure 1 Be sure to match the twisted pair of wires white black white red to the twisted pair in the extension harness m Once you ve soldered all the wires essentiall2. G HARNESS EXTENSION amp INSTALLATION INSTRUCTIONS Cont m Using a wire fish tape tool or similar thin wire coat hanger or safety wire fish all the wires through your new handlebars from the bar ends down to the middle and out to where the main harness connectors will be located It is best to fish the wire tool up through the bars in the middle figure 5 and out by the control area first then secure the newly extended wire harness to that wire tool figure 6 and carefully pull the wire harness back down through the handlebars to the center and out while feeding the harness into the bar at the control area figure 7 Repeat on other side figures 8 m Install new handlebars and reinstall left and right handlebar control switches amp turn signals if removed per your factory authorized service manual m At this point you are ready to plug your left and right handlebar control harnesses backing into the main harness be sure to plug the left plug into the left socket and the right plugs both of them into the right sockets Also don t forget to plug the turn signal harness back in too if separate from the control harnesses Now hook the battery back up and make sure everything functions properly After doing that re secure the wire harness at the same points it was secured and reinstall the fuel tank per your factory authorized service manual and proceed to cable and brake line installation Figure 5 DS Figure 6 Figure 7
3. WARNINGS amp ALERTS W This kit is designed for controlling Harley Davidson OEM components only W The supplied clutch cable must be installed per factory specifications Torque not to exceed 60 in lbs during installation W The operator must use extreme caution when operating a modified motorcycle particularly while familiarizing himself with its altered characteristics W Once installation is complete be certain ALL controls are properly adjusted to the specifications outlined in your factory authorized service manual before attempting to operate your motorcycle Part B30 1067INS Rev C Page 1 of 3 Installation Instructions Extended Cable Line Kit 2012 Later FXD Non ABS models LIMITED GUARANTEE We continually inspect and try to improve our products All parts have been inspected prior to packaging and our guarantee is limited to replacement of defective parts This guarantee is in lieu of all guarantees or warranties implied or expressed Because we cannot control the application of our products buyer assumes risks for any and all damage caused by himself or third party by virtue of failure of these parts We make no warranty as to products distributed by us expressed or implied including without limitation any warranties or merchant ability and fitness for a particular purpose We will however pass on all warranties made by the manufacturer who has sole responsibility for performing such warranties The manufacturer sh
4. all solely be responsible for any damage to person or property arising from design manufacturing and testing of all products and we accept no liability for such damages We shall not be liable for indirect or consequential damages PARTS INCLUDED BLACK FINISH SHOWN BRAIDED STAINLESS KITS ALSO AVAILABLE 888 367 1871 714 367 1871 FAX 714 523 3220 Read all the instructions carefully and be sure you have the proper tools and skills needed before installing this kit on your motorcycle Use your authorized Harley Davidson service manual as a reference while installing this kit DISASSEMBLY INSTRUCTIONS In preparation to install your new handlebars and control extension kit the following must first be removed per your authorized factory service manual m Disconnect Battery m Remove your stock control cables Throttle Idle and Clutch cables noting routing Drain your front brake reservoir amp brake line and remove your stock brake line Locate and gain access to where the main wiring harness connects to the handlebar controls and handlebar mounted turn signals if so equipped This is typically just under the fuel tank on the left behind the steering head loosen tank and lift slightly Remove any wire ties and unplug the left amp right control harnesses noting which plug goes to which side there should be one for the left and two for the right one smaller than the other NOTE Some models have handlebar mounte
5. color wire is where in the connector To remove the wires reference figure 4 first release the connector s a secondary lock b towards the rear of the connector where the wires come out by bending back the latch c on each side of the connector and hinge the secondary lock b outward Look gt in the terminal side of the connector opposite the secondary lock and note the cavity next to each x terminal Insert a small pick straight pin or straightened paper clip into the cavity until it stops Press the internal primary locking tang d away from the terminal socket thus releasing it from the housing and gently tug the wire and terminal socket e free of the connector housing a Now with all the wires free of the connector housing choose the corresponding color extension wire from the Burly kit and firmly plug the proper end onto the wire on the turn signal harness If there is no corresponding color extension wire then choose the closest color and be sure to note the new color next to the old one on the diagram you wrote the original color and positions on below Repeat for all wires The most important thing is that the same wire though now extended gets back into the same position in the connector housing but do not reinstall the wires into the housing yet One by one slide the smaller 1 8 inch heat shrink tubing over each extension connection and apply heat from a heat gun until the tubing has shrunk snugly around the connec
6. d turn signals that are not factory wired through the control harness rather they have their own separate harness that plugs into the main wiring harness independent of the control harnesses You will have to unplug this from the main harness as well typically located under the front right of the fuel tank and extend them separately using the included turn signal extension kit as outlined later m Remove the left handgrip throttle both handlebar switch housings along with the wiring coming out of them NOTE If your handlebar wiring is mounted outside of the bars you need to remove all wire ties that hold the wiring in place If the wiring is run through the bars cut the AMP connector housings off the ends of the left and right control wiring harness and carefully pull the control wire harness out of the handlebars Pull on the harness not on the control housing itself m Remove stock handlebars After completing these tasks proceed with the three installation procedures wiring control cables amp brake line starting on page two 6911 Marlin Circle La Palma CA 90623 info burlybrand com http www burlybrand com Harley Davidson is a registered trademark of the Harley Davidson Motor Company Inc Milwaukee WI This instruction is appropriate for the models noted however you must confirm you have the correct kit part number for your specific bike by contacting Burly Brand Part B30 1067INS Rev C Page 2 of 3
7. fe AN Figure 8 CONTROL CABLE INSTALLATION INSTRUCTIONS m Install the Burly extended control cables as you would stock cables per your factory authorized service manual noting to route the new longer cables in such a manner that no kinking or binding occurs through entire range of steering Check this by turning the handlebars all the way to the left and right while operating the controls Warning The supplied clutch cable must be installed per the factory recommended torque specifications Refer to your factory service manual for proper torque specification Exceeding the recommended maximum torque value of 60 in lbs could lead to clutch cable malfunction resulting in loss of control injury or death m Adjust the Clutch Throttle amp Idle cables per the procedure described in your factory authorized service manual to ensure proper operation BRAKE LINE INSTALLATION INSTRUCTIONS m Install the Burly extended Brake Line as you would stock brake line per your factory authorized service manual noting to route the new longer Brake Line in such a manner that no kinking or binding occurs through entire range of steering Check this by turning the handlebars all the way to the left and right while carefully observing the Brake Line Also make sure there is no binding or stretching of the when fork is completely extended or compressed m Refill the brake system with the recommended fluid and bleed any air out of it per the procedure described in yo
8. tion After doing this to all the wires slide the large 3 8 inch heat shrink tubing over each set of wires 3 left 3 right and apply heat from a heat gun until they are snugly wrapped into a tight bundle At this point if you are running your wires through your handlebars you should do this now before reinstalling them into the connector housing Using the notes you made earlier regarding which color wire goes in which position in the connector housing noting any color variations of the extensions push the l proper color wire contact straight into the connector housing until a click is felt A slight tug will confirm Figure 4 that it is locked into place Repeat for all 6 wires 3 left 3 right Once all the contacts are back in place re lock the secondary lock at the rear of the connector housing Figure 2 a Connector Housing b Secondary Lock c Latch d e p o sss cSS as Primary Locking Tang Wirin Chart j e aaa Terminal Socket amp Wire write the wire s color on the line i corresponding with the position it O came out of the connector OK Ss auauci 888 367 1871 714 367 1871 FAX 714 523 3220 6911 Marlin Circle La Palma CA 90623 info burlybrand com _ http www burlybrand com Harley Davidson is a registered trademark of the Harley Davidson Motor Company Inc Milwaukee WI Part B30 1067INS Rev C SoM Se a 4 BRAND jy WIRIN
9. ur factory authorized service manual After installing these components it is vital that ALL controls must be adjusted to the recommend specifications noted in your factory authorized service manual DO NOT attempt to operate the vehicle before making such adjustments or damage injury or death may result 888 367 1871 714 367 1871 FAX 714 523 3220 6911 Marlin Circle La Palma CA 90623 info burlybrand com _ http www burlybrand com Harley Davidson is a registered trademark of the Harley Davidson Motor Company Inc Milwaukee WI
10. y lengthening the left and right control harnesses one at a time Slide the heat shrink tubing down over the solder point and use a heat gun to apply heat until the tubing has shrunk snugly around both wires and their soldered joint Repeat for all the extended wires Then slide the larger diameter heat shrink tubing over the all the now covered connections and using a heat gun shrink that tubing snugly over them figure 2 Extending the turn signal wires individually not necessary on all models W f your turn signals are factory wired directly into your left amp right control housing or they are not mounted on your handlebars at all there is no need to extend your turn signal wiring and you can skip to the next Step fishing the wires through the handlebars However if your model has the turn signals mounted on the handlebars AND they have their own wiring harnesses going down to the frame then you ll need to use the supplied 6 wire turn signal extension kit to extend these harnesses You will be extending the wires coming from the turn signals individually and to do so you will have to remove the wires 3 left and 3 right from the AMP connector This connector is generally located just behind the steering head and on the right under the front of the fuel tank see figure 3 Before removing any wires note down which color wires are in which sockets in the connector Use the diagram below this paragraph to help by writing down which
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