4.
Remove the left side handlebar switch assembly
fasteners, and
set aside
for later assembly. Remove the
switch assembly from the handlebar.
5.
Using a sharp blade or knife, carefully cut the left side
grip from the handlebar. Thoroughly clean the handlebar
surface of all dirt and adhesive residue.
6.
Refer to the service manual, and follow the instructions
to disassemble the throttle and idle cables
at the
handlebar end only
. Disconnect the switch connector
from the vehicle harness, and remove and
discard
the
right side handlebar switch assembly.
7.
Remove and discard the right side hand grip (throttle
grip).
HEATED HAND GRIP INSTALLATION
1.
Using a 5mm hex key
(1125R and 1125CR models)
or
8mm socket
(all other models)
, loosen the clutch lever
pinch screw to allow the clutch lever bracket to rotate on
the handlebar.
4
5
1
2
3
is04695
Drilling fixture
1.
Set screw
2.
Drilling locator holes (2)
3.
Handlebar left end
4.
Switch housing locating hole
5.
Figure 1. Position Drilling Fixture on Left Side of
Handlebar
NOTE
Cover the front fender and intake cover (and on 1125R and
1125CR models, the left side radiator cover) with clean shop
towels to prevent scratching of the finish.
2.
See Figure 1. Obtain the drilling fixture (1) from the kit.
Check that the set screw (2) does not extend into the
bore of the fixture. With the set screw inboard and toward
the front, slide the fixture onto the left end of the
handlebar (4). Align the set screw with the switch housing
locating hole (5) in the handlebar, and tighten the set
screw securely.
3.
Rotate the clutch lever bracket upward to provide
clearance for the drill. Insert the 9/64 inch drill bit from
the kit into one of the holes (3) in the fixture, and drill a
hole completely through the handlebar wall. Insert the
drill bit into the second hole (3) in the fixture, and drill a
hole through the handlebar wall, directly opposite the
first hole. Remove the fixture from the handlebar.
Thoroughly clean the handlebar surface of all metal
shavings from the drilling operation.
NOTE
Take care not to break the alignment pins on the switch
housings.
4.
See Figure 17. Obtain the left side heated hand grip (1)
and two self-tapping screws (8) from the kit, and note
the two slots on the inboard end of the grip. With the wire
facing down, slide the grip onto the left end of the
handlebar, aligning the holes inside the slots with the
holes drilled in the handlebar in Step 3. Peel back the
collar on the hand grip, and insert one of the screws into
each slot, with the threads protruding through the hole
in the grip and into the hole in the handlebar. Fasten the
screws into the holes in the handlebar using a T-20
TORX
®
drive
head.
Tighten
to
1.6–1.8
N·m
(14–16
in-lbs
).
5.
Refer to the service manual, and follow the instructions
to install the left side handlebar switch assembly to the
handlebar.
6.
Rotate the clutch lever bracket downward into its original
position.
On 1125 CR models only,
line up the clutch
lever bracket with the reference lines on the handlebar.
For ALL models,
tighten the clutch lever pinch screw
to 6.8–9.5 N·m (60–84
in-lbs
).
NOTE
For Ulysses models only:
If a Buell™ Quest™ Global
Positioning System (GPS) Kit is installed on the vehicle, fit
the heated throttle grip wire
between
the two GPS wires.
7.
Obtain the
new
right side handlebar switch assembly
and heated throttle grip from the kit. With the wire facing
down, slide the grip onto the right end of the handlebar.
Refer to the service manual to install the throttle grip,
throttle and idle cables and handlebar switch assembly
to the vehicle. DO NOT fasten wires and cables to the
vehicle at this time.
8.
For Lightning and Ulysses models: For Firebolt
models: For 1125R models: For 1125CR models:
a.
Slightly loosen the four screws fastening the upper
handlebar clamp.
b.
Shift the position of the handlebar as needed to
allow threading the heated throttle grip wire and
right side handlebar switch harness under the
handlebar, behind the front fork, following the path
of the existing wiring into the front fairing. Note that
the rubber-mounted gauge cluster may need to be
pushed upward slightly on the right side to allow
the switch connector to be fed under the cluster.
c.
One at a time,
remove the handlebar clamp
screws. Refer to the service manual, Chapter 1,
for instructions on re-using of fasteners with
threadlocking agents
.
d.
Clean the screw and hole. Apply two drops of
Loctite
®
271 (Red) Threadlocker and Sealant to
the screw threads, and install the screw, but do not
fully tighten. Repeat for the remaining screws.
e.
Align the handlebar for rider comfort. Tighten both
front screws to 14–16 N·m (10–12 ft-lbs), then
tighten
both
rear
screws
to
14–16
N·m
(10–12 ft-lbs).
f.
Remove the cable straps attaching the left and right
side handlebar switch wiring harnesses to the
upper fork clamp (triple clamp).
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