Common Problems After Installing 16 Inch Ape Hangers (And Fixes)
Upgrading to 16-inch ape hangers gives your bike an aggressive stance and a more upright riding position. But if something isn’t installed or adjusted properly, problems can show up fast.
In this guide, we’ll break down the most common problems after installing 16 inch ape hangers — and exactly how to fix them. Whether you ride a Touring, Dyna, or Sportster model from Harley-Davidson, these issues (and solutions) apply across the board. Burly Handlebar Cable Line Kit Black Harley 16″ Ape Bagger Bars 2017-18 FLHX FLH
1. Throttle Doesn’t Snap Back Properly
The Problem
After installation, the throttle feels tight or doesn’t return smoothly.
Why It Happens
- Cables are too short
- Poor routing around the triple tree
- Bars rotated too far back
- Throttle cables overtightened
The Fix
- Turn handlebars fully left and right while testing throttle
- Reroute cables with smoother bends
- Loosen throttle adjusters slightly
- Confirm your cable kit is actually sized for 16” bars
⚠ A sticky throttle is a serious safety issue. Fix immediately before riding.
2. Front Brake Feels Spongy
The Problem
Brake lever feels soft or requires extra squeeze.
Why It Happens
- Air trapped in brake line
- Improper bleeding
- Brake line routed too high creating air pockets
The Fix
- Re-bleed the brake system thoroughly
- Tap brake line gently while bleeding to release trapped air
- Ensure brake line runs smoothly without high loops
If your bike has ABS, confirm the brake line is ABS-compatible.
3. Clutch Engagement Feels Off
The Problem
Hard shifting or clutch slipping after installing ape hangers.
Why It Happens
- Incorrect clutch cable adjustment
- Cable too tight after handlebar repositioning
- Poor routing causing drag
The Fix
- Adjust clutch free play according to service manual
- Ensure smooth routing with no tight bends
- Double-check total cable length if using tall risers
Proper free play is critical for smooth gear changes.
4. Cables Tighten When Turning Handlebars
The Problem
When you turn the bars fully left or right, cables pull tight.
Why It Happens
- Incorrect cable length
- Routing too short across neck
- Riser height not accounted for
The Fix
- Re-route cables behind triple tree
- Ensure cables have slack at full lock
- If necessary, upgrade to longer cables
Always check full steering range before riding.
5. Electrical Issues or Blown Fuses
The Problem
Switches stop working or fuses blow after installation.
Why It Happens
- Wiring stretched too tight
- Poor splicing
- Pinched wires inside handlebars
The Fix
- Inspect wiring at full steering lock
- Use proper solder and heat shrink
- Avoid crimp-only connectors when possible
- Replace damaged wiring extensions
Plug-and-play wiring kits reduce these risks significantly.
6. Handlebar Vibration
The Problem
Excess vibration after installation.
Why It Happens
- Riser bolts not torqued properly
- Bushings worn or damaged
- Bars not seated evenly
The Fix
- Torque riser bolts to manufacturer spec
- Inspect and replace worn riser bushings
- Ensure bars are centered before tightening
Touring bikes are heavier — secure mounting is critical.
7. Wrist, Shoulder, or Back Pain
The Problem
Riding position feels uncomfortable.
Why It Happens
- Bars rotated too far back
- Excessive pullback angle
- Improper riding posture
The Fix
- Loosen risers and adjust angle
- Sit on bike and align wrists naturally
- Keep elbows slightly bent
16-inch ape hangers should improve comfort — not reduce it.
8. Brake Line Rubbing or Contacting Fairing
The Problem
Brake line rubs against fairing or tank when turning.
Why It Happens
- Incorrect routing
- Line too long or too short
- Lack of proper clamps
The Fix
- Re-route brake line behind fork
- Use supplied clamps or zip ties
- Ensure smooth arc without sharp bends
Protecting the brake line prevents long-term wear.
9. Excess Cable Slack (Looks Messy)
The Problem
Too much visible cable slack after install.
Why It Happens
- Using generic-length cables
- Improper routing
The Fix
- Clean up routing behind triple tree
- Secure cables neatly along frame
- Consider custom-length cables if excessive
Clean cable management improves both appearance and safety.
10. Speed Wobble or Steering Instability
The Problem
Bike feels unstable at higher speeds.
Why It Happens
- Riser bolts not torqued evenly
- Front end components disturbed during install
- Loose triple tree hardware
The Fix
- Double-check torque on all handlebar hardware
- Inspect triple tree pinch bolts
- Confirm no cables are interfering with steering
If instability persists, stop riding and inspect thoroughly. Burly Handlebar Cable Line Kit Black Harley 16″ Ape Bagger Bars 2017-18 FLHX FLH
Preventing Problems Before They Start
To avoid common issues after installing 16-inch ape hangers:
✔ Buy a complete 16” cable kit
✔ Confirm ABS compatibility
✔ Include riser height in total measurement
✔ Test full steering lock before riding
✔ Properly bleed brakes
✔ Adjust clutch and throttle carefully
Most post-install problems are caused by poor routing or incorrect cable length.
How Long Should It Take to Settle In?
After proper installation:
- Cables may stretch slightly during first few rides
- Minor clutch adjustment may be needed
- Brake feel should remain consistent
Always inspect cables after the first 100 miles. harleydavidson.com