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Extended Control Cables, Brake Lines, and Handlebar Wiring

Some of the most frequently asked questions we receive are with regard to extended control lines for oversized handlebars. For example, “I would like to put a set of 20” Wild-1 Psycho Chubby Apes on my bike. What length cables and brake line do I need to order?”

If there were some scientific formula to calculate the proper cable and brake line lengths for every possible combination of bars and risers on every single model of bike, it would make ordering a bit easier. Unfortunately, there is not so we recommend that you mount the bars first, then take an accurate measurement for the proper length cables and brake line.   

One method to do so is by using some thin gauge wire.  Once you have the bars in position, route the wire in the same manner that you would like the cables to run.  For example, for throttle cables: start at the carburetor (or throttle body) and route the wire up to the throttle housing on the bars.  Be sure to turn the bars all the way to the left and then back to the right to assure that you will have enough cable to cover your full turning radius.  You are now ready to take your measurement.  Use the same method to measure for the clutch cable and your brake line.  Once you have these measurements, subtract the length of your stock cables and brake line to find out how many inches over stock you will need to order (for example, +6 or +8 over stock).   

Do not overlook the fact that you will also need to extend your handlebar control wiring.  This method of measuring will work for them as well.  We offer handlebar wiring harness extension kits that are available in +4 through +24 inch lengths.  These kits are also available for the new Harley-Davidson Touring models with the electronic throttle control.

 

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