Changing out the handlebars on your motorcycle can be a great way to customize the bike to your liking. While some may think that it is just the simple task of clamping on a new set and hitting the road, there are some other things to consider as well. One of these considerations should be the motorcycle cable lengths and brake line lengths. If you are changing the dimensions of the handlebars, more often than not, you will have to change the lengths of the cables and lines too. This is not as difficult of a task as it may seem. Here are some steps to follow before ordering your new cables and lines from brands like Magnum and Motion Pro.
What You Need to Measure Motorcycle Cables
- Thin gauge wire
- Tape measure
Step by Step Cable Measurement Walkthrough
Step 1: Mock Up Your Handlebars
To get the most accurate measurement, you will want to install your new handlebars on the bike. Bolt on the new bars, risers or controls and set them exactly where you’ll ride them. Turn the bars lock-to-lock to see the full sweep.
Step 2: Simulate Cable Routing with Wire
Run the wire in the desired path that you will want to run the cable. Try to avoid running it against parts with paint or chrome and also hot areas. You will also want to avoid sharp angles in the cable. For example, take the wire and run it from the throttle housing on the handle bars to the carburetor or the throttle body. The clutch cable and brake line can be measured similarly from their corresponding connection points.
Step 3: Measure the Length of the Stock Cable
When doing this, only measure the length of the housing; do not include the length of the free wire at each end. Including the free wire in your measurement will result in a cable that’s too short or too long once installed, which can lead to improper tension, restricted movement, or even failure to engage your controls properly. So always measure only the sheathing, nothing more.
Step 4: Calculate the Difference
Subtract the length of your stock cable from the new measurement that you have made with the wire. This will give you the + or – length that you will now need to order.
Step 5: Order Your Cables
When ordering your cables or lines at Dennis Kirk, enter in the make, model and year of your motorcycle and you will be given the correct fitment options for your bike. Choose the lines and cables with the correct + or – length that you measured.
If you have any questions about the process or would like a recommendation on motorcycle cables and lines, our Tech Team at techsupport@denniskirk.com will be able to assist you in getting your ride back on the road faster.
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16 comments
Could I have your permission to reprint this article on How to measure cables for the newsletter of the Palm Beach Chapter of ABATE of FL Inc.?
Hi Daniel. Please email us at blog@denniskirk.com and we will see what we can do to help you out.
I have a 201
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I HAVE 2010 BONNEVILLE I NEED THE BARS CLOSER TO ME DONT HAVE A CLUE FOR CABLE LENGTH I WOULD THINK 6INCHES WOULD SUFFICE.NOT SURE
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T 100
Hi,Ryan. I have a 2007 Honda vtx r 1300. I have just installed 5.5 inch pull back risers.
Any suggestions for throttle cables..clutch cable and front brake hose? Thanks
Hey Mark, contact our Tech Team and they will be able to give you a run down on all of your options- 320-358-3409 or by email at techsupport@denniskirk.com
Thanks Ryan.
When you say measure the old cable housing does that include the metal elbow or just the housing 1992 Harley Davidson fxlr Low rider custom
What problems would I have if my cables/wires are too long? Can I just hide the slack? I want to change from the handlebars the prev owner installed (16″ Apes) to a drag bar or maybe a beach bar. Thanks
If you can reroute the cables to keep them somewhat tight, you can be alright. But if the slack is turned too sharply, the inner cable can bind on the casing, causing it to stick, which could be dangerous.
I recently put a suicide clutch and jockey shifter on my Evolution chopper. The design of the foot pedal is terrible. And the cable is at a bad angle.is there a good suicide clutch setup available for 5speed cable transmissions. By the way. I’ve been a shovelhead man since childhood. So I am not familiar with the new stuff.thanks
Iam Putin some 18La chopper abbs on my 2013 wide glide how much will cluch cable an threatel cable s an brake cable run
Here is a list of the cable kits that will fit your bike- You can look in the description for the height that you need- https://www.denniskirk.com/cable-kit/2013-harley-davidson-dyna-wide-glide-fxdwg.mmy
When measuring the length do you start at the ball on the cable and end at the ball or just the braided protector of the actual cable??
Do you include the banjo and connector ends in the measurement? I’m replacing stock brake and clutch cables on a 2007 Suzuki SV650, putting on Renthall High 7/8 bars, so everything needs to be longer.
I am building a Santa Hard tail with a stock stretch and 0 up , stock Rake .I am using Drag bars with 9 inch rise and 2 inch back . I have an Ultrama 113 inch motor with a Super G carb and a 6 speed Tranny . I can figure out brake lines but without cables I am stuck on lengths of Throttle and Clutch. Can you help?
I have a stockj 1988 Harley FLHTC with sockj handlebars and a s&s super e carb. I was sold 42 1/2″ cables but they are to short it seems. Can you tell me the proper length. Tahkjs for your help