Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                

Hhaannddlleebbaarr Kkiitt: P/N 2882919-XXX, 2882920, 2882921, 2882922, 2882923, 2883297-XXX

Download as pdf or txt
Download as pdf or txt
You are on page 1of 16

HANDLEBAR KIT

P/N 2882919-XXX, 2882920, 2882921, 2882922,


2882923, 2883297-XXX
IMPORTANT
Due to the technical nature of this kit, Indian®
insists that this installation be performed by a
certified Indian Motorcycle® Technician.

A P P L I C AT I O N
Verify accessory fitment at www.indianmotorcycle.com.
BEFORE YOU BEGIN
Read these instructions and check to be sure all parts and tools are accounted for. Please retain these
installation instructions for future reference and parts ordering information.
KIT CONTENTS
Full installation of this kit will require one of the following additional parts (sold separately):
• Heated Grip Kit PN: 2883442
• Non-Heated Grip Kit PN: 2883441
• Accessory Grip Kit (If accessory grip installed) PN: Various

Full installation of this kit will require the following additional part (sold separately):
• Adhesive Kit PN: 2883462
Kit PN 2882923-XXX shown; Other kits similar except as noted below.
This Kit includes:

Instr 9928169 Rev 01 2017-03 Page 1 of 16


REF QTY PART DESCRIPTION PART
NUMBER
1 1 Handlebar, Cruiser Beach, Polished Stainless Steel (Kit PN 2882921-410) -
Handlebar, Cruiser Beach, Gloss Black (Kit PN 2883448-266) -
Handlebar, Cruiser Mid-Ape, Polished Stainless Steel (Kit PN 2882920-410) -
Handlebar, Cruiser Mid-Ape, Gloss Black (Kit PN 2883449-266) -
Handlebar, Cruiser Pullback, Polished Stainless Steel (Kit PN 2882919-410) -
Handlebar, Touring Mid-Rise, Polished Stainless Steel (Kit PN 2882923-410) -
Handlebar, Touring Mid Rise, Gloss Black (Kit PN 2883450-266) -
Handlebar, Touring Pullback, Polished Stainless Steel (Kit PN 2882922-410) -
Handlebar, Springfield, Buckhorn, Chrome (Kit PN 2883297-156) -
Handlebar, Springfield, Buckhorn, Gloss Black (Kit PN 2883297-266) -

2 1 Cable, Clutch (Only in Kit PN 2882923-410, 2883450-266, 2882920-410, 7082079


2883449-266)
3 2 Cable Tie, Black (Not Shown) 7081504
4 4 Film, Protection, Clear (Only in kits PN 2882923-410 & 2883450-266) 5814472
1 Instructions 9928169

TOOLS REQUIRED
• Safety Glasses • Socket Set, Hex Bit, Metric
• Camera, Digital (Recommended) • Socket Set, Metric
• Hammer, Soft Face (Optional) • Socket Set, Torx® Bit
• Hex Key Set, Metric • Torque Wrench
• Pick Tool Set • Wrench Set, Metric
• Pliers, Side Cutting • Vice, Bench (Optional)
• Screwdriver, Phillips

CONSUMABLES REQUIRED
• Gloves, Chemical Resistant • Solvent Wipe (99% Isopropyl Alcohol)
• Multi-Purpose Grease (If replacing clutch cable) • Tape, Electrical

I M P O R TA N T
Your Indian Handlebar Kit is exclusively designed for your vehicle. Please read the installation instructions
thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For your safety,
and to ensure a satisfactory installation, perform all installation steps correctly in the sequence shown.
A S S E M B LY T I M E
• Without Clutch Cable: Approximately 60 minutes
• With Clutch Cable: Approximately 90 minutes

Instr 9928169 Rev 01 2017-03 Page 2 of 16


I N S TA L L AT I O N I N S T R U C T I O N S
3. Remove and retain three fasteners C and
WARNING
withdraw head light assembly D far enough to
Clutch cable must be routed, installed and disconnect electrical connector. Remove head
adjusted correctly to function properly. Note how light assembly and set aside.
cable is route and secured before removing.
Permanent cable damage may result if inner cable
is bent or twisted during procedure. If cable is
incorrectly routed, installed or adjusted, serious
injury or death may occur.

IMPORTANT
Protect all finished surfaces during these
operations.

1. Turn key or ignition switch to “OFF” position


and remove key. If equipped with keyless fob,
remove fob from proximity of vehicle.
2. Place motorcycle in an upright position on a flat
level surface with front wheel secured in a wheel 4. Unplug handlebar connector E.
vise. TIP
F R O N T B O D Y W O R K R E M O VA L Tie a piece of string or wire to connector before
pulling handlebar out of fairing to ease re-routing
FAIRING MODELS of harness during install.
1. Take photos of wire routing from a front view
and a rear view for reference during re-
assembly.
2. Remove and retain two screws A from head light
bezel B. Pull firmly outward to remove head
light bezel K.

5. To make certain wiring is plugged into correct


terminal during re-assembly, ensure wiring is
labeled on both ends of each terminal. There
are a total of seven terminals coming from
handlebars (four right hand / three left hand).
6. Remove seat as per owner’s manual.

Instr 9928169 Rev 01 2017-03 Page 3 of 16


7. Remove and retain rear console mounting screw NON-FAIRING MODELS
F. 1. Remove windshield assembly, if equipped.
2. Remove and retain two fasteners A from top of
nacelle assembly.

8. Turn handlebars and pull front of the console


Gforward to release it from grommet H at front
mounting location.
3. Remove and retain two fasteners B from each
side of nacelle assembly. Disconnect turn
signals C and light bar bracket (if installed-not
shown) and set aside to prevent damage.
TIP
Photograph wire routing for assembly reference.

9. Unplug harnesses (switches). Remove back of


leather strap J from plastic retainer K on fuel
tank as if removing a shirt button. Remove
console from motorcycle and place on a cloth to
protect from damage.

Instr 9928169 Rev 01 2017-03 Page 4 of 16


4. Rotate headlight bucket assembly D forward H A N D C O N T R O L S R E M O VA L
and lower. Pull rear portion of nacelle assembly
RIGHT HAND CONTROLS REMOVAL
E back to expose handlebar riser F.
1. Starting with lower screw, remove and retain two
screws A and remove master cylinder assembly
B. Carefully hang master cylinder assembly so
that it remains level.

5. Loosen front handlebar clamp fasteners G (Do


not remove screws) and rotate handlebar up
until rear portion of nacelle E can be removed.

2. Remove and retain two screws C from RH switch


cube cover D and separate halves of cover.

6. Disconnect auxiliary light switch (if equipped)


and remove rear portion of nacelle.

3. Remove and retain two screws E from inner half


of RH switch F. Rotate switch side upward and
remove entire assembly. Disconnect wire
connectors from switch cube F.

4. Slide RH throttle tube/grip from handlebar.


Instr 9928169 Rev 01 2017-03 Page 5 of 16
LEFT HAND CONTROLS REMOVAL 3. Unplug clutch switch connector L from LH
switch assembly M by using a small pick to
1. Loosen two screws G. Slide and carefully rotate
release retaining tab. Remove and retain two
clutch handle assembly H enough to gain
screws G and clutch handle assembly H.
access to screws J on back of switch housing
Remove clutch cable from handle and set clutch
K. Use extra caution with clutch handle wire. handle assembly aside.
IMPORTANT
Do Not over-rotate clutch handle assembly around
handlebar or damage to clutch electrical wires will
occur.

4. Remove and retain two screws N from inner half


of LH switch M. Rotate switch side upward and
remove entire assembly. Disconnect wires from
switch cube M.

2. Remove and retain two screws J from LH switch


cube cover K and separate halves of cover.

Instr 9928169 Rev 01 2017-03 Page 6 of 16


5. Remove grip by placing rubber strap wrench 2. Protect clutch release arm C with a shop towel.
around LH grip P and twisting grip to break Rotate release arm inward. Disconnect clutch
adhesive free. Twist grip back and forth while cable D from release arm.
pulling outward. Use a soft hammer if needed to
move handle. Discard LH grip.
NOTE
Removal of LH grip will destroy grip and it should
not be reused.

3. Withdraw clutch cable D from mounting boss


located on primary cover.

C L U T C H C A B L E R E M O VA L
If clutch cable not required, skip to “Handlebar
Removal and Installation” section
1. Remove and retain side stand bumper bolt A
and clutch cable E-clip B.

4. Note routing of clutch cable through frame.


5. Loosen, but do not remove, two screws E, bolt
F and nut G, screws H and Jsecuring LH frame
downtube K to engine and steering head. Do
not remove fasteners.

Instr 9928169 Rev 01 2017-03 Page 7 of 16


6. Remove and retain screw L and P-clamp M. 2. Carefully remove cable clip D and remove
clutch cable E.

FAIRING MODELS
C L U T C H C A B L E I N S TA L L AT I O N
1. Turn handlebars fully right to access cable A.
Carefully pry cable A from wire clip B and IMPORTANT
remove cable. Do not kink, bend, or twist inner cable or outer
cable casing during installation.

1. Route new clutch cable w in same manner as


removed.
2. Torque LH frame downtube K fasteners E, F,
G, H, and J, to specification.
TORQUE
E, F, G, H, and J = 45 ft. lbs. (61 Nm)

NON-FAIRING MODELS
1. Remove and retain four screws A and washers
B from rear of nacelle and separate headlight
housing C from nacelle.

Instr 9928169 Rev 01 2017-03 Page 8 of 16


3. Install retained screw L and P-clamp M. Torque 7. At release arm end of cable, pull inner cable
screw to specification. until fully extended. Be sure upper end of cable
casing is seated in lever perch at handlebar end.
TORQUE
8. Apply multi-purpose grease to lower barrel end
84 in. lbs. (9.5 Nm) of cable.

9. Protect clutch release arm C with a shop towel.


4. Apply multi-purpose grease to lever end of Rotate release arm inward until cable w can be
cable barrel and install it in clutch lever at installed in release arm C.
handlebar.

10. Install clutch cable E-clip B at mounting boss.


5. Install cable casing in lever perch at handlebar. Install side stand bumper and bolt A. Torque
6. Install new cable w in mounting boss located on bolt to specification.
primary cover.
TORQUE
84 in. lbs. (9.5 Nm)

Instr 9928169 Rev 01 2017-03 Page 9 of 16


11. Apply protective film r to surface of dash in 2. Remove and retain two front and two rear cap
areas where clutch cable and brake line route screws E. Remove cap F and risers G from
and may come into contact with painted handlebar.
surfaces.
12. Route clutch cable as per routing noted during
removal. Reinsert cable into applicable clips
and replace cut cable ties.
NON-FAIRING MODELS
1. Reinstall headlight housing C to nacelle. Install
four retained screws A and washers B to rear of
nacelle. Torque to specification.
TORQUE
75 in. lbs. (8 Nm)

3. Pull left and right hand wiring harnesses and


from switch housing wiring slots in handlebar,.
TIP
Feed excess wire into center slot of handlebar
while simultaneously pulling from switch housing
end.

ACCESSORY HANDLEBAR INSTALLATION


1. Insert right hand switch housing wiring harness
into right hand switch housing wiring slot in
handlebar and pull all terminals out of center
wiring slot in handlebar. Pull harness taut until
H A N D L E B A R R E M O VA L A N D I N S TA L L AT I O N switch housing is located adjacent to wiring slot.
Repeat for left hand switch housing wiring.
HANDLEBAR REMOVAL
TIP
1. Remove and retain two screws A and two
washers C from under handlebar risers. Ensure Use a small piece of electrical tape to hold wire
rubber inserts B (retained by screws A) do not terminals together, assist in sliding wires through
fall out. Carefully slide handlebar and riser handlebars.
assembly out of triple clamp frame C. (Fairing/
Nacelle not shown for clarity)

Instr 9928169 Rev 01 2017-03 Page 10 of 16


2. Install risers G and riser cap F onto accessory H A N D C O N T R O L S I N S TA L L AT I O N
handlebar q. Center handlebar wire opening to
riser cap. Rotate handle bars to align clocking RIGHT HAND CONTROLS
marks with separation line of risers G and riser 1. Install new RH throttle tube/grip on handlebar.
cap F as shown with arrow. Loosely install two
front and two rear cap screws E. Torque front TIP
two cap screws to specification. Do not torque “Indian®” name should be horizontal when grip
rear cap screws at this time. properly installed. Rotate grip while sliding on to
ensure it is fully seated.
TORQUE
18 ft. lbs. (24 Nm)

2. Orient throttle housing F with pin in rear half of


housing and hole in bar as shown. Ensure to line
3. Carefully slide accessory handlebar q and riser up slots in throttle tube to throttle housing F.
assembly into triple clamp frame D. Ensure
rubber inserts B are installed. Install two
retained bolts A and washers C (removed in
step 1. of previous section), Torque to
specification. Route handlebar wiring towards
front.
TORQUE
60 ft. lbs. (81 Nm)

4. Torque rear cap screws E to specification.


TORQUE
18 ft. lbs. (24 Nm)

Instr 9928169 Rev 01 2017-03 Page 11 of 16


3. Close throttle housing F and reinstall two 6. Reinstall brake master cylinder assembly B
screws E. Torque screws to specification. using two retained screws A. Align dimple in
handlebar with center of assembly halves as
TORQUE shown with arrow. Starting with top screw,
10 in. lbs. (1 Nm) torque screws to specification.
TORQUE
70 in. lbs. (8 Nm)

4. Twist throttle fully backward and forward to


ensure throttle is properly seated and there is no
dragging. If dragging repeat steps 1 through 3
of this section. 7. Twist throttle fully backward and forward to
5. Reinstall RH switch cube cover D using two ensure throttle is properly seated and there is no
dragging. If dragging repeat steps 1 through 6
retained screws C. Ensure that all wiring is held
of this section.
within switch cube D and not pinched. Torque
screws to specification. LEFT HAND CONTROLS
TORQUE 1. Slide left grip onto handlebar while handlebar is
10 in. lbs. (1 Nm) clean and dry. Install inner portion of switch M
and align grip q. Hold grip in place, remove
switch M and make a mark on handlebar
aligned with tab on grip shown with arrow.
Remove switch and grip.

Instr 9928169 Rev 01 2017-03 Page 12 of 16


2. Spray three sprays worth of primer into grip 5. Quickly reinstall outer switch assembly M with
opening and allow 5 minutes for primer to dry. two retained screws N. Switch assembly notch
should fit over tab on grip flange as shown with
IMPORTANT arrow. Rotate and adjust grip to fit properly.
The next three steps need to be completed Torque screws to specification.
quickly, once adhesive dries, adjustment of grip
will not be possible. Read and understand ALL TORQUE
steps before proceeding. 10 in. lbs. (1 Nm)

3. Apply a thick bead of adhesive (PN 2883462) 15


mm into grip 360° around the grip. Spin LH grip
onto handlebar until grip bottoms out against
handlebar end. Quickly rotate grip so Indian®
name is horizontal and tab is aligned with mark
made in step 1 of this section. Wipe any excess
glue from handlebar or grip after grip is fully
seated.

6. Loosely reinstall clutch handle assembly H


using two retained screws G. Reinstall clutch
wire connector L to switch assemblyM.

4. Quickly orient switch housing M with pin in rear


half of housing and hole in bar as shown. Ensure
to line up slots on LH Grip to switch housing M
as shown.

Instr 9928169 Rev 01 2017-03 Page 13 of 16


7. Reinstall LH switch cube cover K using two C L U T C H L E V E R F R E E P L AY
retained screws J. Ensure that all wiring is held
1. With handlebars pointing straight ahead,
within switch cube K and is not pinched. Ensure measure clutch lever free play at point shown
clutch wire is not pinched by housing. Torque with arrow.
screws to specification.
MEASUREMENT
TORQUE
Clutch Lever Free Play: .019-.059 inch (0.5-1.5
10 in. lbs. (1 Nm) mm)

8. Align dimple in handlebar with center of clutch 2. Compare measurement to specification. If


handle assembly H halves as shown with arrow. adjustment is required, proceed to Step 3.
Starting with top screw, torque screws G to 3. Locate clutch cable adjuster boot A and pull it
specification. back to expose jam nut and barrel adjuster.
TORQUE
70 in. lbs. (8 Nm)

4. Hold cable and loosen adjuster jam nut.


5. Turn cable adjuster in or out until clutch free
play is correct.
IMPORTANT 6. Tighten adjuster jam nut. Torque to
specification.
Allow motorcycle to sit for a period of 24 hours to
allow glue to dry and set properly. TORQUE
48 in. lbs. (5.5 Nm)

7. Slide adjuster boot back over adjuster assembly.

Instr 9928169 Rev 01 2017-03 Page 14 of 16


F R O N T B O D Y W O R K R E - A S S E M B LY 6. Insert headlight bezel by inserting bezel
features into rubber grommets in fairing. Install
FAIRING MODELS retained two flange screws and torque to
1. Route handlebar wiring through fairing in same specification.
routing as referenced in fairing frame. Plug in
TORQUE
handlebar connector E.
36 in. lbs. (4.0 Nm)
TIP
Use piece of string or wire to connector left in
fairing during removal to pull wiring through NON-FARING MODELS
fairing. 1. Insert rear portion of nacelle and connect
auxiliary light switch (if equipped).
2. Loosen front handlebar clamp fasteners G (Do
not remove screws) and rotate handlebar up
until rear portion of nacelle E can be fully
installed.

2. Replace any cut cable ties with new cable ties.


3. Turn handlebar left and right, lock-to-lock, and
determine if any resistance from wire binding. If
resistance is felt or wire interference is found,
determine cause and re-bundle wires as
3. Re-position handlebar to rider preference (If
necessary. Check clearances between hand
needed).
controls and fuel tank. Adjust height if
necessary. 4. Torque front handlebar clamp fasteners to
specification.
4. Re-connect headlight.
5. Install headlight assembly into fairing by TORQUE
installing three aluminum spacers, headlight 18 ft. lbs. (24 Nm)
assembly, three washers then three hex screws.
Torque to specification.
5. Rotate headlight bucket assembly D into place.
TORQUE
84 in. lbs. (9.5 Nm)

TIP
Insert hex screw and washer into top mounting
hole of headlight assembly. Install an aluminum
spacer onto top hole and loosely install screw into
fairing. This will allow placement of the other two
aluminum spacers prior to installing the remaining
washers and screws.

Instr 9928169 Rev 01 2017-03 Page 15 of 16


6. Loosely install turn signals C and auxiliary light 8. Turn handlebar left and right, lock-to-lock, and
bar (if equipped-not shown) and connect determine if any resistance from wire binding. If
electrical terminals. Rotate front nacelle and resistance is felt or wire interference is found,
headlight into place and loosely install two determine cause and re-bundle wires as
retained fasteners B into each side of nacelle necessary. Check clearances between hand
assembly. Do not torque fasteners at this time. controls and fuel tank. Adjust height if
necessary.
9. Torque turn signal/auxiliary lightbar (if
equipped)/nacelle side fasteners B (installed in
step 2 of this section) to specification.
TORQUE
18 ft. lbs. (24 Nm)

10. Install windshield assembly, if equipped.

7. Install two retained fasteners A into top of


nacelle assembly. Torque to specification.
TORQUE
36 in. lbs. (4 Nm)

FEEDBACK FORM
A feedback form has been created for the installer to provide any comments, FEEDBACK FORM
questions or concerns about the installation instructions. The form is viewable on
mobile devices
by scanning the QR code or by clicking HERE if viewing on a PC.

Instr 9928169 Rev 01 2017-03 Page 16 of 16

You might also like