A mess with throttle sensor
INSTALLATION ~
NOTE
Each twist grip sensor contains the terminals for installation of a heated throttle grip available through P&A. While the seal cap protects the terminals from dirt and moisture, it also serves as a retention device for installation of the throttle grip.
1. Verify that seal cap is installed at end of twist grip sensor. If seal cap is not present, proceed as follows:
a. See if seal cap is engaged on index pins inside throttle grip. If found, use a stiff piece of mechanics wire to lasso seal cap and pull free of index pins. Obtain new seal cap if damaged or missing.
b. Check condition of o-ring on seal cap. As o-ring is not sold separately, install new seal cap if o-ring replacement is necessary.
c. Install seal cap engaging legs in slots at end of twist grip sensor. For best results, install one leg first. Depressing second leg slightly with a small flat blade screwdriver, push down on seal cap until fully installed. See Figure 4-21.
2. Connect green twist grip sensor connector.
3. Gently pull Molex connector end of jumper harness to draw twist grip sensor into handlebar. Fit index tabs on twist grip sensor into slots in handlebar. One index tab and slot are smaller than the others to prevent improper assembly. See Figure 4-22.
4. Slide the throttle grip over the end of the handlebar. Rotate the grip to verify that internal splines are engaged with those on the twist grip sensor.
NOTE
It is not necessary to hold the throttle grip onto the handlebar.
Index pins in grip engage receptacle in seal cap of twist grip sensor to prevent grip from sliding oft:
5. Position the lower switch housing beneath the throttle grip, so that ribs at end of throttle grip engage slot in lower switch housing.
6. Position the upper switch housing over the handlebar and lower switch housing.
7. Start the upper and lower switch housing screws, but do not tighten. Verify that the wire harness conduit runs in depression at bottom of handlebar.
8. Position the brake lever master cylinder assembly inboard of the switch housing assembly engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket.
9. Align the holes in the handlebar clamp with those in the master cylinder housing and start the lower screw (with flat washer). Position for rider comfort.
NOTE
Do not pull the switch housings so far inboard as to cause the throttle grip to bind or drag on the handlebar. Rotate the throttle grip to verify that it freely returns to the idle position.
10. Beginning with the top screw, tighten the handlebar clamp screws to 72-80 in-lbs (8-9 Nm) using a T27 TORX drive head.
11. Using a T25 TORX drive head, tighten the lower and upper switch housing screws to 35-45 in-lbs (4-5 Nm).
NOTE
Always tighten the lower switch housing screw first, so that any gap between the upper and lower housings is at the front of the switch assembly.
12. Remove the cardboard insert between the brake lever and lever bracket.
13. FLHR/C: Connect twist grip sensor jumper harness connector and install on T-stud on fork stem nut lock plate (right side). Install handlebar clamp shroud and headlamp. See 2.45 HEADLAMP NACELLE: FLHR/C.
14. FLHX, FLHT/C/U: Draw twist grip sensor jumper harness connector and conduit forward to front of upper fork bracket, and then route under right radio support bracket to area behind fairing support brace. Connect connector
and install on T-stud at top of fairing support brace (inboard side). Install outer fairing. See 2.35 UPPER FAIRING AND WINDSHIELD: FLHX, FLHT/C/U.
15. FLTR: Connect twist grip sensor jumper harness connector.
the Jumper Harness is Pt# 70415-08 retail $23.00
There probably are a few rhetoricals I could put in here, however that would just bring me down to racklefratz level, and by choice I will not venture there.
People who live in glass houses shouldn't throw stones sir.
quote from service manual:
"The external latch on the pin housing of the twist grip sensor connector will break if the twist grip sensor is pulled to hard.
"is pulled TOO hard" would be the correct meaning; "pulled to hard" doesn't have much meaning at all.
Amazing.




