Prewired 1996-2006 12 Rise Pre-Wired Ape Hangers Softail Handlebars Instruction Manual

Prewired 1996-2006 12 Rise Pre-Wired Ape Hangers Softail Handlebars

Specifications:

• Pre-wired handlebar with color-coded wires and connectors
• Handlebar installation torque: 17-21 N.m
• Electrical components prewired with plug-and-play connectors
• Wire grommets for secure connections
• Encapsulating shrink tube for wire protection

Product Usage Instructions

• Step 1: Removal of Original Handlebar
  Follow the steps outlined in your motorcycle manual to disconnect brake and clutch lines, remove grips, mirror mounts, switch housings, and clutch lever assembly. Loosen the riser clamp bolts and remove the old handlebar.

• Step 2: Wire Connection for New Pre-wired Handlebar
  Inspect the prewired handlebar upon arrival. Reconnect color-coded wires with plugs and grommets as instructed in the manual.

• Step 3: Installation of New Handlebar
  Install the new handlebar, ensuring wire bundles are guided down through the upper fork bracket. Seat the handlebar with the knurled area centered. Adjust the handlebar angle and tighten to torque specifications.

• Step 4: Hand Control and Housing Installation
  Install throttle cables, grips, switch housing, brake lever assembly, and clutch line according to your motorcycle’s manual. Verify smooth rotation of throttle sleeve.

• Step 5: Electrical Connection Reattach all electrical components removed earlier. Test turn signals, brake lights, and other electrical functions.

• Step 6: Safety Check
  Ensure all wiring and cables are secure, check brake functionality, test turn signals, and ensure smooth movement of the handlebar without obstruction.

FAQ:

• Q: What should I do if I am unsure about any installation step?
  A: Consult your local dealer or contact Technical Support via email at [email protected] before proceeding.

• Q: Is there a warranty for this product?
  A: Please refer to the warranty information provided by the product manufacturer.

Note:
Before proceeding, refer to your motorcycle manual and consult a certified mechanic if necessary. Safety is paramount!

INSTALLATION INSTRUCTION

Step 1 – Removal of the Original Handlebar:

• Optionally, remove the windshield.
• Disconnect the brake and clutch lines according to your motorcycle manual.
• Slide off both grips.
• Remove mirror mounts, switch housings, and the clutch lever assembly.
• Loosen the riser clamp bolts and remove the old handle.

Step 2 – Wire Connection for New Prewired Handlebar:
First of all, take a second to inspect how your handlebars are set up when they arrive. All of the wiring harnesses (including the CAN-Bus and Turn Signal Wire Harness) are prewired, precut, and have PLUG & PLAY connectors preinstalled at one end, with color-coded wires grommet at the other end.

Please refer to the following steps to complete the re-connection of the Color-coded Wires:

1. Re-connection of Color-coded wires with Plugs: Take a photo for the color-coded old wires before re-connection. Remove the old wire pins from the connector with nipper pliers carefully and insert new color-coded wire pins based on the photo you just take

Re-connection of color-coded wires with grommets:

• Take a photo for the color-coded old wires before re-connection.
• Remove the grommet from the end of new wires.
• Cut one wire back about 1/2 inch (12 mm) from the end of the wires.
• Connect the new wire and old wire based on the photo you just take.
• Slip the two-inch (50.8mm) long section of encapsulating shrink tube over the
• Use a heat gun to shrink the tubing. Continue heating the tubing until it is tightly secured to the wire.

Step 3 – Installation of New Handlebar:

• Install the handlebar, guiding the wire bundles down through the upper fork bracket.
• Seat the handlebar with the knurled area centered.
• Install the riser clamp and bolts but keep them loosely tightened.
• Adjust the handlebar angle to run parallel to the front forks.
• Tighten to Torque: 17-21 N.m.

Step 4 – Hand Control and Housing Installation:

• Note : If opting for a taller handlebar, consider longer lines and wires. Install throttle cables and the right grip/throttle assembly.
• Install switch housing and brake lever assembly. Consult your motorcycle’s owner’s manual or seek help from a certified mechanic if needed.
• Verify that the right grip/throttle sleeve rotates freely.
• Install the left handlebar grip.
• Install switch housing and clutch lever assembly. Refer to your motorcycle’s owner’s manual.
• Install a sufficiently long clutch line and connect it.
• Install the brake line according to your motorcycle’s owner’s manual.

Step 5 – Electrical Connection:

• Reattach all electrical components removed in Step 1.
• Ensure all pins are attached and test turn signals, brake lights, and other electrical components.

Step 6 – Safety Check:

• Ensure all wiring and cables are secure, and nothing is obstructing the bike’s mechanical parts.
• Test the brake to ensure it’s working properly.
• Test turn signals and press the brake to check the brake light.
• Move the handlebar from left to right and back to ensure smooth movement without obstruction.

WARNINGS!

• Do not proceed if you’re unsure about the steps. Consult local dealer.
• The product provider is not responsible for any damage or injury resulting from improper use.
• Ensure no part of the product obstructs your bike’s functioning.
• Follow these steps, and you’ll be back on the road in no time! Stay safe out there!
• Technical Support Email: [email protected]

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