Tech Tips: Biltwell AlumiCore

Biltwell AlumiCore grips are available in two styles to fit select make and model-year Harley-Davidson motorcycles: Throttle-by-Wire (TBW) and Dual Cable. AlumiCore grips will not fit any other non-Harley Original Equipment or aftermarket throttle or hand control. If you have never disassembled or serviced the hand controls on a Harley-Davidson motorcycle, we recommend consulting a professional mechanic for this procedure. Harley throttles and hand controls are precise components, and assembling them incorrectly can lead to serious headaches.

These instructions show how to install TBW AlumiCore grips, but the steps and procedures are similar for Dual-Cable hand controls. These tips DO NOT show you how to remove your old grips. If you don't know how to disassemble the hand controls on your motorcycle, DO NOT try to install AlumiCore grips—consult a service professional to do the job for you.
INSTALLING ALUMICORE GRIPS

STEP 1: Carefully disassemble the left- and right-side hand control clamshells that hold the old grips on your motorcycle. Remove old grips and clean both bar ends with contact cleaner and a ScotchBrite pad to remove dirt, grease, glue and other debris. If your handlebars feature aftermarket bar-end attachments (mirrors or sliders, for example), remove these pieces—they will not work with AlumiCore grips. Slide the left (clutch side) AlumiCore grip onto the bar end until it bottoms out against the handlebar.

STEP 2: Capture the left grip's locating flange inside the clamshells, making sure both halves of the hand control assembly engage tightly with each other around the inside end of the grip. Make sure the buttons inside the clamshells are seated properly, and that the clamshells don't pinch any of the wires inside. Reinstall and tighten the bolts that secure the clamshell assembly to the handlebar.

STEP 3: Insert the wedge mechanism of the left (clutch side) end cap assembly into the hole on the end of the AlumiCore grip, making sure the end plug is completely seated against the beveled end of the grip's aluminum core. Hold the end cap firmly in one hand and tighten the Allen bolt until the wedge cinches tightly inside the handlebar.

STEP 4: Slide the right (throttle side) AlumiCore grip tube onto the bar end, making sure the forged aluminum gear interface inside the grip tube engages completely with the end on the TBW mechanism. If you're installing dual-cable AlumiCore grips, please refer to a Harley service manual for the correct make and model-year of your motorcycle. Harley-Davidson dual-cable throttles vary by specification and model year, and require fine-tuning after assembly for safe operation.

STEP 5: Capture the right grip's alignment flange inside the clamshell assembly. Hold the clamshells tightly around the alignment flange on the grip and twist the throttle to confirm smooth operation. If the grip twists tightly or does not snap back smoothly, something may be pinched or misaligned inside the clamshell assembly. Open it up and double-check cables, wires, buttons, and other internal components to make sure nothing is out of place. When you're confident the AlumiCore throttle grip functions correctly, reinstall and tighten the bolts that secure the clamshell to the handlebar.

STEP 6: Put a drop of blue LocTite or medium-strength thread compound on the threads of the recessed Allen cap screw for the throttle grip end cap and screw it into the end of the right AlumiCore grip. Hold the end cap firmly in one hand and gently tighten the bolt with an Allen wrench—do not over-tighten.

Step 7: Before riding, double-check all the hardware that secures your hand controls and grips to the handlebar. Check the Allen bolts that secure the end caps on your AlumiCore grips. If the rubber sleeves on your AlumiCore grips moved on the knurled aluminum tubes during assembly, gently twist and pull the sleeves so their molded flanges touch the inside edge of the end cap and grip flange.

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REPLACING ALUMICORE RUBBER SLEEVES

The rubber sleeves on Biltwell AlumiCore grips are injection molded with Thermoplastic Vulcanizate (TPV) rubber. This pliant yet rugged synthetic material is soft enough to ride bare-handed, but tough enough to provide exceptional durability, even under extreme riding conditions. When the comfort sleeves on your AlumiCore grips show signs of wear from friction or damage due to heat, moisture or sunlight, replace them with Biltwell brand AlumiCore grip sleeves ONLY—do not try to use other grips for this purpose.

Step 1: Remove both AlumiCore grip end caps by loosening their mounting screws with a 3/16" Allen wrench. The Allen bolt/end cap assembly on the right (throttle side) grip will detach completely from the throttle tube. Loosen but DO NOT REMOVE the left (clutch side) end cap bolt only enough to allow the internal wedge assembly to slide out of the handlebar. Carefully cut off the old grip sleeve from the right (throttle side) AlumiCore grip. Repeat this step on the left (clutch side) grip.

Step 2: Carefully clean the exterior surfaces of both AlumiCore grip tubes with contact cleaner and a ScotchBrite pad to remove old glue and rubber debris. Do not spray contact cleaner directly into the end of either AlumiCore grip tube—doing so could make the left grip slip on the handlebar and/or compromise throttle performance.

Step 3: Spray a quick blast of aerosol WD-40 into the open end of one new grip sleeve. Wipe any dripping fluid or overspray off the TPV grip sleeve before moving to the next step…

Step 4: Quickly slide the open end of the lubricated grip sleeve onto the end of the AlumiCore grip tube. A firm twisting and pulling motion may be necessary to seat the new grip sleeve flush against the knurled grip tube's inside flange. Repeat steps 3 and 4 for the remaining grip sleeve.

Step 5: Insert the 1/2-inch-long Allen screw through the right (throttle side) end cap and apply a drop of blue Loc-Tite or medium-strength thread compound to the threads. Screw the end cap assembly into the right-side grip tube and tighten the Allen screw.

Step 6: Insert the clutch side wedge/end cap assembly into the end of the left handlebar, making sure the inside of the end cap stops firmly against the grip tube. Hold the left end cap tightly in one hand and tighten the Allen bolt.

If you hate dry instructional text and boring spec photography, we've created two videos that summarize both installations processes right here:

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