HANDLEBAR CABLE KITS — WHY ONE SIZE DOESN'T FIT ALL

Changing your motorcycle handlebars isn't always as simple as choosing a new design and ordering a cable extension kit.

While most customers concentrate on rise height, pullback and appearance, there's another important consideration: making sure the cables, brake lines and electrical wiring are the correct lengths for the new handlebars.

At Fortress Motorcycle, we've encountered many different Harley-Davidson configurations over the years, and one thing we've learned is that there's no universal cable kit that fits every motorcycle perfectly.

COMPLETE CABLE KITS — ARE THEY ALWAYS THE BEST OPTION?

Complete handlebar cable kits are available from several manufacturers and are generally sold according to handlebar rise height.

For example, kits may be advertised for 12–14", 14–16" or 18–21" handlebars.

That means a 13" or 15" handlebar will often fall within an advertised range. However, being within that range doesn't necessarily guarantee the ideal cable length.

The motorcycle's original handlebar dimensions, pullback, width and cable routing all influence what's required.

We've also found that complete kits for shorter custom handlebars, particularly around 8" or 10" rise, can sometimes be more difficult to source.

A kit that's slightly too short can create tension, while excessive length can result in unnecessary slack and untidy routing.

For that reason, having individual cables measured and manufactured to the correct length can sometimes produce a better installation.

OLDER HARLEYS VERSUS NEWER MODELS

Older Harley-Davidson models commonly use conventional cable-operated throttles and clutches.

A complete handlebar conversion may therefore require a clutch cable, separate throttle and idle cables, an upper brake line, switch wiring extensions and turn-signal extensions.

These kits can be more expensive because of the additional mechanical cables involved.

Many newer models use electronic throttle control, commonly known as throttle-by-wire, eliminating the traditional throttle and idle cables.

Where necessary, plug-and-play electronic throttle extensions can be used instead.

Clutch arrangements also vary between models, with some motorcycles using conventional clutch cables and others using hydraulic systems.

This is why the exact model and year are important when selecting a cable kit.

SOMETIMES THE ORIGINAL CABLES ARE LONG ENOUGH

Something many customers don't realise is that fitting taller handlebars doesn't automatically mean replacing every cable.

On certain Harley-Davidson models, the original cables and wiring have sufficient length to accommodate a considerable increase in handlebar rise.

For example, we've encountered Pro Street Breakout installations where the original throttle-by-wire connection can accommodate handlebars approaching 20", depending on the setup.

Some Street Glide and Road Glide models can also accommodate handlebars around 12" rise while retaining certain factory cables or wiring.

Occasionally, releasing factory cable ties around the wiring loom near the fairing provides additional usable length.

However, these examples shouldn't be treated as universal fitment specifications.

Every installation must be checked individually, particularly with the handlebars turned fully in both directions to ensure nothing becomes stretched, trapped or restricted.

DO YOU REALLY NEED BOTH BRAKE LINES?

Many complete cable kits include both upper and lower front brake lines.

But when changing handlebars, it's often only the upper brake line that requires additional length.

The original lower brake line may be perfectly suitable to retain, provided it's compatible with the new components and remains in good condition.

Some customers prefer replacing both lines so the colours and finishes match, particularly when using braided hoses.

That's a personal choice, but it doesn't necessarily mean both lines need replacing.

Establishing exactly what's required before buying a complete kit can save unnecessary expense.

Any replacement brake lines must, of course, be suitable for the motorcycle's braking system, including ABS where fitted.

INTERNAL WIRING AND CUSTOM CABLE ROUTING

At Fortress Motorcycle, internal switch and turn-signal wiring is standard practice on virtually every handlebar we manufacture, with some exceptions for certain Japanese motorcycles.

Traditionally, Harley-Davidson handlebars use wiring slots beneath the left- and right-hand switch housings, allowing the electrical wiring to run inside the bars.

However, Harley-Davidson has changed these arrangements over the years.

Certain later Touring models incorporate additional forward-facing wiring slots, while models such as the Street Glide ST and Road Glide ST have different switch housing and throttle control configurations.

These details have to be considered when manufacturing replacement handlebars.

Optional internal clutch and hydraulic line routing

For certain cable-operated Softail models, including standard Milwaukee-Eight Softails, we can incorporate an additional side slot into the handlebar upright for suitable clutch cable routing.

On selected motorcycles equipped with hydraulic clutches, we can also prepare handlebars to accommodate internally routed front brake and hydraulic clutch lines.

This can produce a particularly clean appearance, with fewer visible hoses around the handlebars.

We explain these options to customers and show photographs of previous installations so they can decide whether they prefer internal or external routing.

These specialist routing options carry a small additional charge, as they require more fabrication work than our standard electrical wiring slots.

The installation must also use suitable cables or hydraulic hoses, with the correct routing and fittings.

OUR PREFERRED CABLE AND HOSE MANUFACTURERS

Over the years we've developed preferences for particular manufacturers based on quality and fitment.

Our first choice for complete cable conversion kits is generally Magnum Shielding, followed by LA Choppers and Burly Brand.

For specialist hydraulic brake and clutch hoses, we use UK manufacturers HEL Performance and Venhill Engineering, particularly when specific lengths or different banjo fitting angles are required.

Sometimes a custom-manufactured hose is simply a better solution than an off-the-shelf component.

OUR ADVICE — GET THE CABLE LENGTHS RIGHT

Although complete cable kits are convenient, they're not always the most economical or best-fitting solution.

Sometimes the original cables are sufficient. Sometimes only an upper brake line and electrical extensions are needed. And sometimes the best result comes from individually measured cables and hoses.

If you're experienced in custom motorcycle work, you may be perfectly comfortable measuring and installing these components yourself.

However, if you're new to Harley-Davidson motorcycles or unsure about cable lengths, we strongly recommend using an experienced motorcycle mechanic.

This is particularly important when specifying individual brake lines, clutch cables and hydraulic components.

Correct routing, steering clearance, throttle operation and braking performance are essential.

At Fortress Motorcycle, we believe a quality set of custom handlebars deserves an equally well-executed installation.

GET THE MEASUREMENTS RIGHT. GET THE ROUTING RIGHT. AND NEVER COMPROMISE SAFETY FOR APPEARANCE.

Handcrafted. Personal specification. Built different. Built Fortress.

SHOPIFY EXCERPT

Changing your Harley-Davidson handlebars? Discover why complete cable kits aren't always the perfect solution, when original cables can be retained, and how Fortress Motorcycle approaches brake lines, electrical extensions and internal cable routing.