EVO: Body Parts

HANDLEBARS, LEVERS & CABLES

Handlebars

Here is a table of OEM handlebars:

ModelYear(s)Handlebar Serial Number / Type
XL 8831986-2003(56082-83) Flat Bar 1) 2) 3) 4)5)6) 7) 8) 9) 10) 11)
2004-2009(55845-04) 12) 13) 14) 15) 16) 17)
XL883C1999(56185-98) Drag Style 18)
2000-2003(56185-98A) Drag Style 19) 20) 21) 22)
2004-2009(55840-04) 23) 24) 25) 26) 27) 28)
2010(55840-04A) 29)
XLH 883 Deluxe1986-1991(56082-83) Flat Bar 30)
1992-1995(56081-82) Buckhorn (pullback) 31) 32) 33)
XL 883 Hug1988-1996(56081-82) Buckhorn (pullback) 34)35)36) 37)
1997-2003(56081-82A) Buckhorn or Buckram 38)39) 40) 41) 42) 43) 44)
XL 883L2005-2006(56038-05) 45) 46)
2007-2010(56051-06) 47) 48) 49) 50)
2011-2014(57209-11) 51) 52) 53) 54)
XL 883N2009(56014-09) 55)
2010-2015(56014-09A) 56) 57) 58) 59) 60) 61)
XL 883R2002-2003,2005-2014(56085-83A) (black) 62) 63) 64) 65) 66) 67) 68) 69) 70) 71) 72) 73)
XLH 11001986-1987(56081-82) Buckhorn (pullback)74)
XL 12001988-1996(56081-82) Buckhorn (pullback) 75)76) 77) 78)
1997-2003(56081-82A) Buckhorn or Buckram 79)80) 81) 82) 83) 84) 85)
XL 1200C1996-1998(56164-96) 86)87)88)
1999(56185-98) Drag Style 89)
2000-2003(56185-98A) Drag Style 90) 91) 92) 93)
2004-2009(55840-04) 94) 95) 96) 97) 98) 99)
2010, 2012-2014(55840-04A) Pull Back100) 101) 102) 103)
XL1200C Anniversary2013(55840-04A) Pullback 104)
XL 1200CA2013-2014(57472-11) Drag 105) 106)
XL1200CB2013-2014(56079-93) Mini Ape107) 108)
XL1200CP2012-2014(55840-04A) Pull Back 109) 110) 111)
2012-2014(56079-93) Mini Ape 112) 113) 114)
2012-2014(57472-11) Drag Style115) 116) 117)
XL 1200L2007-2011(56051-06) 118) 119) 120) 121) 122)
XL 1200N2007-2012(56085-83A) 123) 124) 125) 126) 127) 128)
XL 1200R2004-2009(56004-00)129) 130) 131) 132) 133) 134) 31/32“ width, 4” rise, and 8“ pullback 135)
XL 1200S1996-1997(56082-83) Flat Bar 136)137)
1998-2003(56110-98) Flat bar (black) 138) 139) 140) 141) 142) 143)
XL 1200V2013-2014(56079-93) Mini Ape 144) 145)
XL 1200X2010-2015(56014-09A) 146) 147) 148) 149) 150) 151)
XL-502007(56004-00) 152)
XR 12002009-2010(56085-83A) 153) 154)
XR 1200X2010-2013(56085-83A) 155) 156) 157) 158)

The MoCo has a catalog of handlebars, brake lines & control cables: 159)
https://www.harley-davidson.com/app-content/eStore/Harley-Davidson%20Handlebar%20Installation%20Requirements.pdf


Handlebar Pics and Specs

  • Handlebars are sized:
    • Overall length: Lay the bar on a flat surface and measure from left handgrip edge to right handgrip edge for total outside distance.
    • Rise: Total outside distance as measured vertically from top to bottom.
    • Center width: Total straight distance between the upsweep bends from left to right on area that clamps onto the risers from left to right beginning of the upsweep.
    • Pullback: Total outside distance from the front clamping area to edge of the handgrip toward rider (front to back distance).
    • Center spacing for risers: Outside distance (left to right) between both knurled areas where the risers attach.


Stock Bars

1998-2003 S Model Handlebars (56110-98) Flat Bar 160)

Aftermarket Bars

See Aftermarket Handlebars, Risers and Mods in the REF section of the Sportsterpedia

Clutch Levers

Starting in 2007, the Clutch Lever had a switch implemented to allow it to be monitored. See the clutch switch function here.

Notes:

  • 2004-2017 Clutch lever retaining bolt (42807-04) has a circlip (11379) on the end of it to keep it in place. The circlip is not listed in the hardware section of the parts catalog but an 8mm external circlip will fit it. 161)


Clutch Cables


Brake Levers

162)

See here for Brake Lever Switches: brake_switch_-_front_rear


Brake Cables


Grips

Throttle Cables

1986-2006 Throttle Cables For Carbs
(See the pictures below with regards to the cable system description that follows.) 163)

These Sportsters use a dual throttle cable system. The throttle cables connect the throttle grip to the carburetor. The first cable, the Throttle Cable, pulls on the carb throttle cam which is connected to the end of the throttle plate shaft. As the cable pulls on the cam, the shaft is rotated and the throttle plate opens.

The second cable is named the Idle Cable and is connected to the carb throttle cam in the opposite direction from the throttle cable. The idle cable only serves as a backup function; it is not used to close the throttle unless the throttle cam return spring should break. However, the idle cable does provide some balance of tension against the throttle cable to prevent the throttle tube from rotating past the idle point.

The throttle cam spring is quite strong & actually provides the tension on the throttle cable as you turn the throttle grip toward WOT. The idle cable is a safeguard in case this spring (on the carb) should break and the throttle plate remains open.

When installing the throttle/idle cable, the adjuster screws are turned all the way in to minimize the length of the sheath, in order to expose as much cable as possible, to make it easier to assemble the cable to the throttle tube & the carb throttle cam. Each cable has a ball end (used at the throttle tube) and a barrel end (that is used at the throttle cam).

The ball end of the cable is passed up through the lower switch housing. If you have the screw-in type cable, it would now be screwed into the lower switch housing. Then, the installable barrel is placed over the ball end and the barrel slid into the appropriate notch on the throttle tube. The slot in the installable barrel is inserted into the notch first. The throttle cable is located on the outward (front) side of the switch housing and the idle cable is located on the inward (rearward) side. Install both cables in like fashion.

164)165)

Now route your cables past the forks and thru the fuel tank mounts down to the carburetor.

The throttle cable is attached to the outward side of the throttle cam and the idle cable is attached to the inward (closest to the engine) side of the throttle cam. There are similar notches in the throttle cam as those located in the throttle tube and the crimped barrels on the cable ends fit into those notches.

Route the idle cable up and into the side slot of the carb throttle bracket. Be sure to insert the spring (at the end of the idle cable) into the bracket cup so the idle cable sheath is buffered from the bottom of the cup.

Route the throttle cable in a similar manner into the side slot of the bracket and make sure the cable sheath fits down into the bracket cup (there is no spring on the throttle cable end).

Be sure both cable adjusters are fully minimized. Set the front wheel straight ahead. Turn the throttle grip to fully open (WOT) and hold it there. Turn the adjuster on the throttle cable so that the throttle cam is just touching the carb throttle stop. Release the throttle grip.

Turn the front wheel fully to the right. Turn the adjuster on the idle cable so that the idle cable sheath just touches the spring in the carb throttle bracket cup.

Start the engine and make sure it idles properly with the throttle grip fully clockwise (closed). Now open the throttle and quickly release it. It should spring back with a snap and resume a proper idle. Turn the front wheel fully left to fully right. The idle should not change. If the idle changes or the grip does not spring back into the idle position immediately upon release, readjust the idle cable adjuster to assure proper functioning and check that there is no tight bend or kink in the cable preventing smooth operation.


2007-2013 Throttle Cables For EFI


2014-later Throttle Cables for CANbus


Some Throttle Cable Related XLForum Threads:

Broken Idle Cable
http://xlforum.net/forums/showthread.php?t=459983

Barnett - Custom Cables - Illustrations & Guide
http://www.barnettclutches.com/custom-cable-measuring-guide.html

Motion Pro - Custom Cables - Illustrations & Guide
https://www.motionpro.com/c/custom-cables

Quick Throttle
http://xlforum.net/forums/showthread.php?t=645755

166)


1) , 30) , 34) , 74) , 75)
1986-1990 EVO Sportster Parts Catalog (99451-90)
2) , 31) , 35) , 76)
1991-1992 HD Sportster Parts Catalog pg 71
3) , 32) , 36) , 77)
1993-1994 HD Sportster Parts Catalog pg 71
4) , 33) , 37) , 78) , 136)
1995-1996 HD Sportster Parts Catalog pg 75
5) , 38) , 79) , 87)
1997 HD XLH Parts Catalog pg 71
6)
1998 HD XLH Parts Catalog (99451-98B) pg 75
7) , 40) , 139)
1999 HD Sportster Parts Catalog pg 79
8) , 19) , 41) , 82) , 90) , 140)
2000 HD Sportster Parts Catalog pg 79
9) , 20) , 42) , 83) , 91) , 141)
2001 HD Sportster Parts Catalog pg 81
10) , 21) , 43) , 62) , 84) , 92) , 142)
2002 HD Sportster Parts Catalog pg 81
11) , 22) , 93)
2003 HD Sportster Parts Catalog pg 83
12) , 129)
HD 2004 Sportster Parts Catalog pg 77
13) , 45) , 64) , 95) , 130)
2005 HD Sportster Parts Catalog pg 81
14) , 46) , 65) , 131)
HD 2006 Sportster Parts Catalog pg 81
15) , 132)
HD 2007 Sportster Parts Catalog pg 81
16) , 48) , 67) , 119) , 124) , 133)
2008 HD Sportster Parts Catalog pg 83
17) , 28) , 49) , 55) , 68) , 99) , 120) , 125) , 134) , 153)
2009 HD Sportster Parts Catalog pg 129
18) , 89)
1999 HD Sportster Parts Catalog pg 81
23)
HD 2004 Sportster Parts Catalog
24)
2005 HD Sportster Parts Catalog pg 83
25) , 96)
HD 2006 Sportster Parts Catalog pg 83
26) , 97)
HD 2007 Sportster Parts Catalog pg 85
27) , 98)
2008 HD Sportster Parts Catalog pg 85
29) , 100)
2010 HD Sportster Parts Catalog pg 127
39) , 80)
1998 HD XLH Parts Catalog pg 75(99451-98B)
44) , 63) , 85) , 143)
2003 HD Sportster Parts Catalog pg 81
47) , 66)
HD 2007 Sportster Parts Catalog pg 83
50) , 56) , 69) , 121) , 126) , 146) , 154) , 155)
2010 HD Sportster Parts Catalog pg 125
51) , 57) , 70) , 122) , 127) , 147) , 156)
2011 HD Sportster Parts Catalog pg 123
52) , 58) , 71) , 128) , 148) , 157)
2012 HD Sportster Parts Catalog pg 123
53) , 59) , 72) , 149) , 158)
2013 HD Sportster Parts Catalog pg 179
54) , 60) , 73) , 150)
2014 HD Sportster Parts Catalog pg 127
61) , 151)
2015 HD Sportster Parts Catalog pg 130
81)
1999 HD Parts Catalog pg 79
86)
1995-1996 HD Sportster Parts Catalog pg 77
88) , 138)
1998 HD XLH Parts Catalog pg 75 (99451-98B)
94)
HD 2004 Sportster Parts Catalog pg 79
101) , 109) , 112) , 115)
2012 HD Sportster Parts Catalog pg 125
102) , 104) , 105) , 107) , 110) , 113) , 116) , 144)
2013 HD Sportster Parts Catalog pg 181
103) , 106) , 108) , 111) , 114) , 117) , 145)
2014 HD Sportster Parts Catalog pg 129
118) , 123)
2007 HD Sportster Parts Catalog pg 83
137)
1997 HD XLH Parts Catalog (99451-98B) pg 75
152)
HD 2007 Sportster Parts Catalog pg 83
159)
Thanks to jzink0883 of the XLForum for the heads up - threadid=2068909
162)
Image Annotated by IXL2Relax of the XLForum
163)
pics at right by IXL2Relax of the XLForum
164)
Pics from http://xlforum.net/forums/showthread.php?t=321130 by SportyTrace of the XLForum - Annotated by IXL2Relax
165)
Pic from http://xlforum.net/forums/showthread.php?t=1367932 by Batousaii of the XLForum - Annotated by IXL2Relax
166)
Pic by FlashEdwards of the XLForum
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