How to Install a 16 Inch Ape Hanger Cable Kit (Step-by-Step Guide)

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How to Install a 16 Inch Ape Hanger Cable Kit (Step-by-Step Guide)

Installing a 16 inch ape hanger cable kit is one of the most popular handlebar upgrades for riders who want aggressive styling and a more comfortable upright riding position. But if you don’t install the cables correctly, you can end up with tight throttle response, brake issues, or wiring problems.

This step-by-step guide will walk you through how to install a 16” ape hanger cable kit properly, especially on models from Harley-Davidson. Whether you’re working on a Touring bike, Dyna, or Sportster, the process is very similar. Burly Handlebar Cable Line Kit Black Harley 16″ Ape Bagger Bars 2017-18 FLHX FLH

What Is a 16 Inch Ape Hanger Cable Kit?

A complete 16 inch ape hanger cable kit typically includes:

  • Extended throttle cables
  • Extended clutch cable
  • Extended brake line
  • Wiring extensions
  • Hardware and fittings

When upgrading to 16” apes, stock cables are too short. That’s why a complete cable kit is essential for proper fitment and safety.

Tools You’ll Need

Before starting, gather the following:

  • Socket set
  • Allen wrench set
  • Torque wrench
  • Screwdrivers
  • Brake fluid
  • Cable lube (if applicable)
  • Zip ties
  • Shop towels

Optional but helpful:

  • Motorcycle lift
  • Service manual for your model

Step 1: Disconnect the Battery

Always disconnect the negative battery terminal before touching wiring.

This prevents:

  • Electrical shorts
  • Blown fuses
  • Accidental starter engagement

Safety first.

Step 2: Remove the Stock Handlebars

  1. Remove mirrors and hand controls.
  2. Disconnect throttle and clutch cables.
  3. Remove front brake line from master cylinder (have towels ready).
  4. Loosen riser bolts and remove stock handlebars.

Take photos before disassembly — it helps during reinstallation.

Step 3: Remove Old Cables and Wiring

Carefully trace and remove:

  • Throttle cables
  • Clutch cable
  • Brake line
  • Handlebar wiring

Pay attention to factory routing. Clean routing prevents cable binding later.

Step 4: Install the 16 Inch Ape Hanger Handlebars

Before installing cables:

  1. Position the 16” ape hangers in the risers.
  2. Lightly tighten riser bolts (don’t fully torque yet).
  3. Sit on the bike and adjust angle for comfort.

Proper angle prevents wrist fatigue and shoulder strain.

Step 5: Install Extended Wiring

If your bars are pre-wired, feed wires through carefully.

If not:

  1. Use wiring extensions from your cable kit.
  2. Solder and heat-shrink connections (recommended).
  3. Avoid crimp-only connectors when possible.

Make sure wiring moves freely when turning the bars left and right. Burly Handlebar Cable Line Kit Black Harley 16″ Ape Bagger Bars 2017-18 FLHX FLH

Step 6: Install Extended Throttle Cables

  1. Attach throttle cables to throttle housing.
  2. Route cables cleanly along frame.
  3. Connect to carburetor or throttle body.
  4. Adjust cable tension properly.

Important:

Turn handlebars fully left and right while twisting throttle. It should snap back smoothly with no tension change.

If throttle tightens when turning bars, reroute immediately.

Step 7: Install Clutch Cable

  1. Route extended clutch cable along frame.
  2. Connect at clutch perch.
  3. Adjust free play according to manufacturer specs.

Too tight = clutch slipping
Too loose = hard shifting

Take your time here.

Step 8: Install Extended Brake Line

This step requires attention.

  1. Attach new extended brake line to master cylinder.
  2. Route line cleanly with no sharp bends.
  3. Connect to caliper.
  4. Torque fittings to spec.

After installation:

  • Fill master cylinder
  • Bleed front brakes thoroughly

Spongy lever = air still in system.

If your bike has ABS, confirm compatibility before installation.

Step 9: Final Torque and Adjustment

Now:

  • Torque riser bolts to manufacturer spec
  • Double-check all cable routing
  • Turn bars fully left and right
  • Check for pulling, binding, or tension

Nothing should stretch or tighten when steering.

Step 10: Test Ride Carefully

Before hitting the road:

  • Check brake pressure
  • Test throttle snap-back
  • Check clutch engagement
  • Inspect for leaks

Start with a short, slow ride to confirm everything feels normal.

Common Installation Mistakes to Avoid

❌ Using Stock-Length Cables

They will not safely reach with 16” apes.

❌ Poor Cable Routing

Tight bends cause premature wear and sticking.

❌ Not Bleeding Brakes Properly

Air in brake line is dangerous.

❌ Forgetting to Check Steering Range

Always check full left and right movement.

How Long Does Installation Take?

  • Experienced mechanic: 2–3 hours
  • DIY beginner: 4–6 hours

Take your time. Rushing causes mistakes.

Is a 16 Inch Ape Hanger Cable Kit Worth It?

Absolutely — if installed correctly.

Benefits include:

  • Aggressive stance
  • Improved riding posture
  • Custom look
  • Better road presence

When paired with a quality cable kit, the upgrade is clean and reliable. harleydavidson.com

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