Arlen Ness RAD III Quick Start Manual Download Page 1

 

6050

 

Dublin

 

Boulevard,

 

Dublin,

 

Ca.

 

94568

 ‐ 

Technical

 

assistance:

 

925.479.6379

 ‐ 

www.arlenness.com

 

RAD

 

III

 

HANDLEBAR

 

CONTROLS

 

For

 

96

up

 

Harley

 

Davidson

 

models

 

Thank

 

you

 

for

 

purchasing

 

this

 

Arlen

 

Ness

 

product.

 

We

 

believe

 

that

 

our

 

products

 

are

 

the

 

very

 

best

 

available

 

and

  

are

 

engineered

 

to

 

provide

 

a

 

lifetime

 

of

 

use.

 

Basic

 

hand

 

tools

 

and

 

a

 

service

 

manual

 

for

 

your

 

year

 

and

 

model

 

motorcycle

 

are

 

all

 

you

 

need

 

to

 

com

plete

 

this

 

installation.

  

Parts:

  

1

‐ 

Brake

 

master

 

cylinder

 

assembly

  

1

‐ 

Clutch

 

perch

 

assembly

 

1

‐ 

Switch

 

housing

 

set

  

1

‐ 

lower

 

left

 

switch

 

housing

 

(for

 

audio

 

only

 

08

748

 

kit

 

only)

 

1

‐ 

Hardware

 

kit

 

1

‐ 

Instructions

 

1.

 

Disconnect

 

negative

 

battery

 

cable.

 

Confirm

 

the

 

bike

 

has

 

no

 

power.

 

 

 

 

 

 

 

 

 

2.

 

Remove

 

OEM

 

mirrors

 

and

 

turn

 

signals

 

from

 

clutch

 

perch

 

and

 

brake

 

master

 

cylinder.

 

(if

 

so

 

equipped)

   

 

 

 

3.

 

Start

 

with

 

the

 

throttle

 

side:

  

 

 

 

 

 

 

        

 

 

 

        

(All

 

models

 

except

 

08

up

 

touring)

 

Slack

 

throttle

 

cable

 

all

 

the

 

way.

 

Remove

 

upper

 

and

 

lower

 

switch

 

housing

 

screws.

 

Lift

 

the

 

upper

 

switch

 

housing

 

up

 

and

 

rotate

 

it

 

forward

 

to

 

gain

 

access

 

to

 

the

 

throttle

 

cable

 

ends.

 

Remove

 

the

 

cable

 

ends

 

from

 

the

 

grip

 

and

 

remove

 

grip.

    

 

 

 

       

 

 

 

       

(08

up

 

touring)

 

Remove

 

upper

 

and

 

lower

 

switch

 

housing

 

screws.

 

Lift

 

the

 

upper

 

switch

 

housing

 

up

 

and

 

rotate

 

it

 

for

ward,

 

push

 

the

 

lower

 

housing

 

down

 

and

 

carefully

 

remove

 

grip.

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

        

IMPORTANT

 

NOTE:

 

During

 

the

 

next

 

step

 

it’s

 

important

 

not

 

to

 

get

 

brake

 

fluid

 

on

 

any

 

painted

 

surfaces.

 

It

 

will

 

dam

age

 

paint!

 

If

 

you

 

get

 

brake

 

fluid

 

on

 

the

 

paint

 

wash

 

it

 

off

 

immediately.

  

 

 

 

 

 

 

 

4.

 

Break

 

banjo

 

bolt

 

loose

 

at

 

the

 

master

 

cylinder

 

then

 

snug

 

it

 

back

 

down

 

so

 

it

 

does

 

not

 

leak.

 

Remove

 

master

 

cylinder

 

from

 

handle

 

bar

 

and

 

remove

 

brake

 

line.

 

Secure

 

brake

 

line

 

pointing

 

straight

 

up

 

so

 

it

 

does

 

not

 

drip.

    

 

 

 

 

 

 

 

 

5.

 

(All

 

models

 

except

 

08

up

 

touring)

 

Remove

 

throttle

 

cables

 

from

 

lower

 

switch

 

housing.

 

 

 

 

 

 

6.

 

NOTE:

 

During

 

this

 

step

 

pay

 

close

 

attention

 

to

 

how

 

the

 

wires

 

are

 

routed,

 

how

 

the

 

wires

 

are

 

secured

 

and

 

basically

 

how

 

everything

 

fits

 

inside

 

of

 

the

 

housings

 

before

 

disassembly.

 

This

 

will

 

help

 

during

 

reassembly.

 

Remove

 

OEM

 

switches

 

and

 

buttons

 

from

 

OEM

 

switch

 

housings

 

then

 

install

 

them

 

into

 

the

 

RAD

 

III

 

housings

 

in

 

reverse

 

order

 

of

 

re

moval.

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7.

 

(All

 

models

 

except

 

08

up

 

touring)

 

After

 

all

 

the

 

switches

 

and

 

buttons

 

are

 

installed

 

into

 

new

 

switch

 

housings

 

install

 

throttle

 

cables

 

into

 

lower

 

switch

 

housing.

 

Install

 

the

 

throttle

 

grip

 

then

 

attach

 

cables

 

to

 

it.

  

 

 

 

 

(08

up

 

touring)

 

After

 

all

 

the

 

switches

 

and

 

buttons

 

are

 

installed

 

into

 

new

 

switch

 

housings

 

install

 

the

 

throttle

 

grip.

 

 

 

8.

 

Position

 

switch

 

housings

 

around

 

grip

 

and

 

start

 

screws

 

but

 

do

 

not

 

tighten.

 

NOTE:

 

Be

 

sure

 

not

 

to

 

pinch

 

any

 

wires.

  

 

 

9.

 

Attach

 

brake

 

line

 

to

 

new

 

master

 

cylinder

 

using

 

new

 

banjo

 

bolt

 

and

 

seal

 

washers

 

(provided).

 

Snug

 

for

 

now.

 

Attach

 

new

 

master

 

cylinder

 

to

 

handlebars

 

making

 

sure

 

to

 

engage

 

tab

 

on

 

lower

 

switch

 

housing

 

in

 

groove

 

in

 

master

 

cylin

der.

 

Rotate

 

control

 

to

 

desired

 

position

 

then

 

starting

 

with

 

top,

 

torque

 

bolts

 

to

 

6

7

 

ft.lbs.

 

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