New Bars don't fit...need help!!
 

Just tried to install these bars on my '10 Iron


http://www.ebay.com/itm/360643657042...%3AMEBIDX%3AIT


Like the title says, they didn't fit. The brake line wasn't long enough. I could have bolted them up with a slight lean forward, but the brake line would have been stretched pretty good and its not what I would like. I saw Delboys install of the Keystones and my new ones are only 1/8 rise over those. I also talked to a guy who installed them on a 48 with stock everything. I think the risers are different but by how much?


What is a cheap and good way to make them work?


Put the stock bars back on, here's a pic of the slack in the brake line.

Longer lines ought to do the trick.

It's not uncommon when people swap their bars that they have to change everything: clutch, break, electrical, throttle,.... If it's just the brake line in your case, I'd say you got off easy! Just get a longer brake line.

Is there any slack you can borrow from further down the fork, etc?

Its a hardline from the top triple tree to the underside of the bottom triple tree. Attached are a couple pics


How hard is it to change a brake line or how much does it cost to have it done? Not super mechanical so don't want to screw anything up, especially with braking.


I talked to a guy who installed the bars on his 48 with stock everything, but I'm guessing the risers are different as is the speedo clamp?


Also saw a post of a guy who had Zeds installed on a 72 with stock lines/cables.
Could I just get shorter risers? Want black obviously.

Oh gotcha, didn't know that's how the Irons brake line was.

I installed 14" Burlys on my 72 with all stock lines and cables, I just had to extend the controls wiring. The brake line on a 72 is rubber from head to toe, so you can motivate slack where you need it.

All I really need is an extra inch or so from the top of the hardline to the master cylinder. I would say the rubber line is about 6 inches, is it easy to replace that with say a 9 inch line either rubber or steel?


Or since I'm messing with the brae line, should I just replace the whole line?

I've got a 48. When I did my bars I took off the front brake line and took it to a local hose shop. They cut off the rubber section and crimped on a longer section. Pressure tested and I was out the door in 15 minutes for about $30. I got a few extra crush washers and bolted everything back together. I think you'll find the hardest part of the job is bleeding the air out of the front brake. If it sounds to difficult and you have extra money pay someone. If not there are plenty of videos on YouTube and threads on the forum. Good luck.

Yeah I'm guessing I could just take it off and bring it to a shop and get a longer piece like you said Ployd4.


Members can be pretty creative sometimes and was hoping someone had a cheap easy fix where I didn't have to drain/bleed the brakes.

The easy fix you are looking for is straightening the hard line, a friend of mine had to do exactly that on his iron. Didn't have to detach lines or bleed anything, just straightened it VERY CAREFULLY with some channel lock pliers. It can be done you just have to be very careful and keep an eye out for the line beginning to crack. Worst case scenario you crack it and get a new brake line but then you would be in the same shoes as you would be without trying to straighten the line so give it a shot.

Another one trying to take chances - didn' we have the same question only weeks ago? If you change bars and the brake lines don't fit, GET PROPERLY FITTING NEW LINES. Brakes are a safety essential for the bike and for your own health.

Don't gamble to save few bucks and/or the effort to replace & bleed the lines. @ Greeley - IMHO your advice is outright dangerous, because when you get to see any cracks in the bent line, it's already too late.

Just my 0.02, and as the flight instructor sez: "It's your butt, dude!"

Definitely get a new brake line as soon as you have the funds to do it. In the meantime you could bend the stock brake line. You don't need any pliers or any thing. I installed the HD Mini Apes on my Iron and had to extend my wiring but I was able to keep the stock clutch, throttle/idle cables, and my brake line. Just unscrew the little P clamp from the bottom of the Trees and let the line hang, straighten the metal part (I was able to bend it ever so gently with my hands) just enough to give you the extra slack you need.
But I wouldn't ride it that way for too long, get the proper line as soon as you can.

I agree with you, I didn't go this route on my bike, I replaced the whole line w/ a braided line. Just throwing it out there as it has been done and with success, take it for what it's worth.

If you have a plumber or HVAC friend, see if they have a tubing bender:
http://i158.photobucket.com/albums/t...bingbender.jpg
Seems like the perfect excuse to get a black, braided stainless steel brake line. I wouldn't dick around with my brakes for 100 bucks, and you'll get better braking from braided.

i may have a sotck new take off 48 line - i can measure it if you want it.. it does not have the metal like the 883s do - i just chose not to use it the bars i have now work fine with the stock line

although it does fit, i didnt like the way it looked im weird about looks with my stuff hahaha

i can measure it tomoro and if you think the length is fine just drop me a pm and i will ship it to you - early xmas present lol

ok just checked online not sure which sportster version it came off of - hmmm

it may have been from dealer when i had the mini apes i dunno lol


all i know is it does fit and does not have the metal in between the hoses so u can move an whirl it around as u please -- again i will look to measure the length and repost with it .. if it works for you. its yours

Worst case scenario you pinch the line and don't realize it. Which would be easy to do since it such is small tubing. Then your brakes don't work. Other people have also straightened their line without any problems. I just think it is a terrible idea on a motorcycle.

Yep - while brake line tubing is meant to be bent to fit in the first place (with the proper tools, thanks, HarleyScuba), it is not meant to be bent back and forth. The metal microstructure has a limited capacity to take bending, and anything bent you're straightening again will suffer some loss in stability, ultimately leading to cracking and failure. Very simple.

100% ACK - just a terrible idea. Think of what you're spending on your bike, so don't seek shortcuts just on the brake system.

Yeah I'm just a cheap bastard, but safety is definitely key. I just hate spending more money on one thing, because then it takes away from something else I would like to do.


I ultimately want to learn how to work on the whole bike, but since the brakes are a safety component, it makes me kind of weary. I think there is much more of a reward if you can do the work yourself, but there's usually a lot more risk of something going wrong.


Plus some of the shops rip you off and since its my first bike, don't know what shop in my area is good.


thanks for the help guys!

I see you're in Virginia. If you're within a hour or so of Stafford or Fredericksburg, it'd be worth your while to check out Olde Towne Cycle. These guys know their stuff and are very customer service oriented. I've known Brian for years, and I've never heard anything but the truth come out of his mouth. It's a No Bull Shit zone. They're much more concerned with their reputation than money.
If you're near Manassas, maybe I can be of some assistance. I'm not a professional mechanic, but shoot me a PM if you want someone to stand over your shoulder and tell you you're doing it wrong. LOL. Or, we can go for a putt and see Brian.

haha thanks HarleyScuba, I'm actually in sterling, so pretty close to you. Is Oldtowne where you normally go? I just got the bike and am looking for a good shop to use. Right by me is RnR Cycles, but they had a couple not so good reviews on google. There's also Brooks Cycles in Chantilly, heard anything about them?


Elfnyc, I'm definitely interested, where in NY are you? I'll be up in Northern Jersey(wayne, Hoboken area) this weekend, could maybe meet up as well.
So are they are full soft line?

im in yonkers near the casino - i have the front line sitting at my mothers house - i didnt get a chaned to measure today im still workin - i will def stop there tomoro and get length of it and post it up .. i do have a photo somewhere of it let me see if i can find it

The intersection of Route 17 and Route 1, where Olde Towne Cycle is located, might be a hour and 15 minutes to 1 1/2 hours from you (about 50 minutes for me and it's a sweet route), but I wouldn't go any where else unless I was on a road trip and I had no choice. They're moving the shop to bigger digs next week (not far from the existing shop), but they won't loose their dedication to customer satisfaction. I know I sound like a commercial, but I have full faith and confidence in their work and integrity. Hell, I'd give them the keys to my house. Check out their website and/or send me a PM if you want to know more.
I don't know who runs the other shops you mentioned and I haven't heard any scuttle-butt either way about their services. Take a ride by and see what they're about. Maybe ask them about installing tires, or a brake line, and check the vibe.

Thanks HS, I have a little time Friday morning, might check out brooks and see how it does. If I don't like it, I'll try to go to Oldtowne next week sometime.


Elfnyc, just let me know the length whenever you get around to it. I'll be up in Montclair around 5-6 Friday, maybe we could meet up somewhere then, or you can mail it and I can always send you the shipping paypal. Thanks!


Also how well do those brake bleeding kits work? There's one at Harbor Freight for like $18

hey blue i got to measure the line its 35 inch long from center eye to center eye

its yours if you want it just pm me your addy if it will work and i will send it asap!