Installing heated grips on a Harley-Davidson motorcycle is a specialized process that requires attention to detail, proper wiring, and adherence to manufacturer specifications. This article provides a comprehensive, step-by-step guide based on official technical documentation from Harley-Davidson and Dominator Cycles. It is intended for U.S.-based motorcycle technicians, DIY riders, and enthusiasts who are installing or upgrading heated grips on 2014–2021 Touring models, Softail, and other compatible models. The instructions cover wiring identification, heat-shrink techniques, interconnect splicing, and final assembly. The focus is on accuracy and safety to ensure a fully functional and secure installation.
Overview of Heated Grip Systems
Harley-Davidson’s heated grip systems are designed to improve rider comfort in cold conditions by providing adjustable heat output. The system typically includes a control dial, a power source, and heated grip assemblies with internal resistive heating elements. The installation process varies slightly depending on the model year and whether the motorcycle is pre-wired for heated grips or requires additional wiring.
Dominator Cycles has developed a pre-wired handlebar system for 2014–2021 Touring models that simplifies the installation of heated grip extensions. The installation guide provided by Dominator includes instructions for identifying wiring, marking, splicing, and securing connections with heat-shrink tubing. Meanwhile, Harley-Davidson’s service documentation includes more technical procedures, including the use of specific part numbers, torque specifications, and electrical connection kits.
Step-by-Step Installation Process
The installation of heated grips involves several distinct phases: identifying and preparing wiring, splicing and securing connections, routing the wiring through the handlebars, and final assembly. Below is a detailed breakdown of each step, using information from both Dominator and Harley-Davidson technical documentation.
Step 1: Identifying and Marking the Heated Grip Wiring
Before any splicing or installation, it is critical to correctly identify the wiring associated with the heated grips. This step is particularly important for models that already have pre-installed heated grip wiring or for models being upgraded.
Locate the wiring extensions on the handlebars. For pre-wired models, you will typically see:
- Red and black wires
- White and black wires
These wires may appear similar to the factory wiring, so careful differentiation is necessary.
Mark the wires using heat-shrink tubing as recommended by Dominator. To do this:
- Pull out the left-side wiring first, leaving the right-side wiring in place.
- Take a small piece of white heat-shrink tubing (included in the kit) and slide it over one of the wires.
- Use a heat gun or radiant heating device to shrink the tubing, marking the wire for easy identification.
- Repeat the process for the right-side wiring.
This method ensures that the correct wires are connected during the splicing process.
Step 2: Preparing the Connections
Once the wires are identified and marked, the next step is to prepare the connections for splicing. This involves using heat-shrink tubing to secure the connections and prevent short circuits.
Apply larger heat-shrink tubing over the combined wires, ensuring that both the red and black wires are covered.
Use smaller heat-shrink tubing for the individual red and black wires. Ensure that the wires are aligned correctly with the existing harness, matching the color-coded pairs.
Shrink the tubing using a heat gun or radiant heating device. Apply heat from the center of the crimped splice outward to each end until the meltable sealant exits both ends of the connector.
This step is crucial for insulating and securing the wiring, preventing damage from vibration or environmental exposure.
Step 3: Cooling and Securing the Wiring
After the heat-shrink tubing is applied, it is necessary to cool the connections to ensure they harden and maintain their shape.
Use compressed air (if available) to cool the heat-shrunk connections quickly. This method is faster and ensures the tubing hardens uniformly.
If compressed air is not available, allow the connections to cool naturally. Cooling is important because it makes the tubing rigid, which is necessary for the installation of the grips.
Once the connections are cooled and rigid, the wiring is ready to be routed through the handlebars.
Step 4: Routing the Wiring Through the Handlebars
Routing the wiring through the handlebars requires patience and the use of lubricant to prevent damage to the wiring.
Identify the heated grip and its corresponding extension wires. This is typically done by following the color-coding and markings applied in previous steps.
Feed the wires one at a time through the handlebars. This approach reduces the risk of twisting or damaging the wiring.
Apply lubricant to the wiring to assist with the routing. This helps the wires slide through the handlebar more easily.
Push the wiring through the handlebar rather than pulling it to prevent strain on the connections. This minimizes the risk of breaking the wires or damaging the insulation.
Once the wiring is fully routed, the next step is to install the heated grips themselves.
Step 5: Installing the Heated Grips
With the wiring in place, the final step is to install the heated grip onto the handlebar.
Slide the heated grip onto the handlebar, aligning it with the existing components.
Gently tap the grip into place to ensure it is seated correctly. Avoid using excessive force to prevent damage to the handlebar or wiring.
Double-check that the grip is fully seated and secure. Ensure that the wiring is not pinched or twisted and that the connections are not exposed.
At this point, the installation is complete, and the heated grip is ready for testing.
Advanced Installation Considerations
For models that require additional wiring or modifications beyond the standard installation, there are several key considerations based on Harley-Davidson service documentation.
Splicing and Routing for Specific Models
Different models may require different splicing techniques and routing procedures. For example:
- Dyna and 2016–2017 Softail models: Red wire must be connected to the red/yellow wire in the electrical harness (part number 72673-11).
- 2014 and later Touring models: Red wire must be connected to the V/BE wire in the electrical harness (part numbers 69200722 or 69201599A).
- 2018 and later Softail models: A specific adapter harness (69201750) is required to connect the heated grip interconnect to the factory harness.
These connections must be made with sealed splice connectors and heat-shrink tubing for insulation and durability.
Installing the Throttle Grip and Switch Housing
The installation of the heated throttle grip requires additional attention to ensure proper function and safety.
Verify that the right grip/throttle sleeve rotates freely and does not bind on the handlebar or switch housing. Failure to do so can result in improper throttle function.
Remove the old throttle grip and insert the new heated grip. Ensure that the internal splines are engaged with those on the twist grip sensor.
Position the lower and upper switch housings beneath and over the grip, respectively. Ensure that the grooves on the outboard side of the switch housing fit over the flange on the end of the grip.
Tighten the switch housing screws using a T-25 TORX drive head. The torque specification is 4–5.4 N·m (35–48 in-lbs). This ensures the housing is secure without over-tightening.
Install the brake master cylinder housing inboard of the switch housing assembly, ensuring the tab on the lower switch housing engages with the groove at the bottom of the master cylinder housing.
Adjust the switch housing and brake hand control position for rider comfort. This ensures that the rider has optimal control and comfort.
Final Steps and Reassembly
Once the heated grips are installed, the final steps involve reassembly of other components and verification of the installation.
Secure the wiring with cable straps to prevent movement and potential damage. The kit may include jumpers for additional wire length if needed.
Install the seat and fuel tank, following the instructions in the service manual. After installation, pull up on the seat to verify that it is secure.
Install the outer fairing and ensure that all components are in place and functioning.
Test the heated grip functionality by turning the ignition on and off. The grips should produce heat when the engine is running at cruising speed.
Verify that the heat settings on the control dial range from 1 (minimum) to 6 (peak). This ensures the system is functioning as intended.
Reinstall the headlight and any other components that were removed during the installation process.
Troubleshooting and Safety Considerations
Proper installation of heated grips is critical for both performance and safety. Below are some troubleshooting tips and safety considerations based on the service documentation.
Common Issues and Solutions
- Heated grips not producing heat: Verify that the wiring connections are secure and that the control dial is set to the correct setting. Check the battery voltage and ensure that the engine is running at cruising speed.
- Throttle not returning to idle: This could indicate that the throttle sleeve is binding. Adjust the position of the switch housing or verify that the internal splines are properly engaged.
- Short circuits or damaged wiring: Inspect the heat-shrink tubing and sealed splice connectors for damage. Replace any damaged components immediately.
Safety Guidelines
- Always disconnect the battery before working on electrical systems to prevent accidental short circuits or damage to the motorcycle’s electronics.
- Use proper tools and follow torque specifications to avoid over-tightening or damaging components.
- Verify that the throttle functions properly before starting the engine. Do not operate the vehicle if the throttle does not return to idle.
- Test the heated grip system before riding in cold weather to ensure it is functioning correctly.
Conclusion
Installing heated grips on a Harley-Davidson motorcycle is a precise and technical process that requires attention to detail, adherence to specifications, and proper use of tools and materials. By following the step-by-step instructions provided in this guide—based on official documentation from Dominator Cycles and Harley-Davidson—technicians and DIY riders can ensure a safe and functional installation.
Key steps include identifying and marking wiring, splicing and securing connections with heat-shrink tubing, routing the wiring through the handlebars, and reassembling components such as the throttle grip, switch housing, and fairing. Additional considerations for specific models, such as Softail and Touring, require attention to part numbers and wiring connections.
Safety is paramount throughout the installation process. Always verify that the throttle functions correctly before starting the engine, and test the heated grip system before riding in cold conditions. By following these guidelines, riders can enjoy improved comfort and performance in a variety of weather conditions.