Arlen Ness RAD III User Manual

6050DublinBoulevard,Dublin,Ca.94568‐Technicalassistance:925.479.6379‐www.arlenness.com
RADIIIHANDLEBARCONTROLS
For96‐upHarleyDavidsonmodels
ThankyouforpurchasingthisArlenNessproduct.Webelievethatourproductsaretheverybestavailableandareengineered
toprovidealifetimeofuse.Basichandtoolsandaservicemanualforyouryearandmodelmotorcycleareallyouneedtocom‐
pletethisinstallation.
Parts:
1‐Brakemastercylinderassembly
1‐Clutchperchassembly
1‐Switchhousingset
1‐lowerleftswitchhousing(foraudioonly08‐748kitonly)
1‐Hardwarekit
1‐Instructions
1. Disconnectnegativebatterycable.Confirmthebikehasnopower.

2. RemoveOEMmirrorsandturnsignalsfromclutchperchandbrakemastercylinder.(ifsoequipped) 

3. Startwiththethrottleside:    
(Allmodelsexcept08‐uptouring)Slackthrottlecablealltheway.Removeupperandlowerswitchhousing
screws.Lifttheupperswitchhousingupandrotateitforwardtogainaccesstothethrottlecableends.Remove
thecableendsfromthegripandremovegrip.    
(08‐uptouring)Removeupperandlowerswitchhousingscrews.Lifttheupperswitchhousingupandrotateitfor‐
ward,pushthelowerhousingdownandcarefullyremovegrip.

IMPORTANTNOTE:Duringthenextstepit’simportantnottogetbrakefluidonanypaintedsurfaces.Itwilldam‐
agepaint!Ifyougetbrakefluidonthepaintwashitoffimmediately.

4. Breakbanjoboltlooseatthemastercylinderthensnugitbackdownsoitdoesnotleak.Removemastercylinder
fromhandlebarandremovebrakeline.Securebrakelinepointingstraightupsoitdoesnotdrip.  

5. (Allmodelsexcept08‐uptouring)Removethrottlecablesfromlowerswitchhousing.

6. NOTE:Duringthissteppaycloseattentiontohowthewiresarerouted,howthewiresaresecuredandbasically
howeverythingfitsinsideofthehousingsbeforedisassembly.Thiswillhelpduringreassembly.RemoveOEM
switchesandbuttonsfromOEMswitchhousingstheninstallthemintotheRADIIIhousing
sinreverseorderofre‐
moval.

7. (Allmodelsexcept08‐uptouring)Afteralltheswitchesandbuttonsareinstalledintonewswitchhousingsinstall
throttlecablesintolowerswitchhousing.Installthethrottlegripthenattachcablestoit.
(08‐uptouring)Afteralltheswitchesandbuttonsareinstalledintonewswitchhousingsinstallthethrottlegrip.

8. Positionswitchhousingsaroundgripandstartscrewsbutdonottighten.NOTE:Besurenottopinchanywires.

9. Attachbrakelinetonewmastercylinderusingnewbanjoboltandsealwashers(provided).Snugfornow.Attach
newmastercylindertohandlebarsmakingsuretoengagetabonlowerswitchhousingingrooveinmastercylin‐
der.Rotatecontroltodesiredpositionthenstartingwithtop,torqueboltsto6‐7ft.lbs.

Arlen Ness RAD III Specifications

General

Brand	Arlen Ness
Model	RAD III
Category	Motorcycle Accessories
Language	English

Summary

Preparation and Throttle Side Disassembly

Initial Disconnection and Removal

Disconnect battery, remove mirrors, and turn signals.

Throttle Side Housing and Cable Removal

Remove throttle cables and master cylinder from the throttle side.

Throttle Side Reassembly and Master Cylinder Installation

Installing New Throttle Side Components

Install switches, cables, and master cylinder on the throttle side.

Securing Throttle Side Controls

Position switch housings and attach master cylinder to handlebars.

Clutch Side Disassembly and Reassembly

Clutch Side Housing and Cable Removal

Remove OEM switch housings, lever, and cable from the clutch side.

Installing New Clutch Side Components

Install new perch, lever, and cable, securing the switch housings.

Final Installation and Testing

Brake System Bleeding and Adjustment

Fill master cylinder, bleed brake system, and adjust controls.

Final Checks and Reassembly

Reconnect battery, test switches, and install mirrors/signals.