Length of clutch cables, brake line, and throttle cables

[lawdog]

I am looking at making some handlebar risers for my 2009 XB12R similar to what American Sport Bike is selling. Looking at the cables and brake line I am pretty sure I am going to need longer cables. I was wondering if you could tell me if the Lightning or Ulysses had longer cables then the Firebolt. If so any rough measurements of the different lenghths?


Thanks!
Brett

 

[racepro716]

I am in the process of making those exact parts. I'm almost done. If you don't raise the bars "center to center" if you know what I mean by more than 1.75 in. you won't need longer cables. I had to relocate the clutch cable holder on the front engine mount and route the brake line on the outside of the fork though. I should be done this week and hope to post pics along with the lower footpeg mod I did. Wayne

 

[lawdog]

Thats good to know. I was thinking about 3 inches actually. 1.5" rise and 1.5" pullback. What thickness plate did you go with? I was thinking 3/8" should be strong enough.
Brett

 

[racepro716]

Ok, on this project I'm approaching total failure and I'm pretty pissed. I'm beating my head against the wall trying to route the throttle cables around the bottom of the tripple clamp. If I position the right bar to clear the throttle cables the master cylinder or the brake lever hit the fairing. The front brake light switch is also getting close to beaing hammer bait. I really don't think this is going to work with stock cables/brake line. I may try fabbing longer bars. I'm using 5/16,6061 aluminum plates. How are yours coming along? Wayne

 

[Squattybodyjr]

I put 2 inch risers on mine from ROX and did not have to buy new cables, but i did have to adjust them a little. Just unbolt all the lines first then pull the handle bars up. then you can see how lenght you have to work with. I think a 3 inch rise will work without buying new cables. I ride a xb12scg

 

[racepro716]

Squatty, thanks but Lawdog and myself are riding XB12R's. I would bet our cables are way shorter than yours because our bars clamp directly into the triple clamp as opposed to how yours are mounted. Wayne

 

[pur pony]

I was just looking into this issue on my bike and Motion Pro will make you any length cables you want for what i though was a very reasonable price... if needed...

 

[lawdog]

Can you give more info purpony?
Thanks
Brett

 

[racepro716]

Ok, this WILL work!! I just spent a bit of time on the bike and you CAN raise the bars 1 3/4 inches without buying new cables. There is a TON of fabricating to do but get out there and do it! As I thought, the stock bars are too short, you'll have to fab new ones about 1 1/2 inches longer because of clearance issues. (Master cylinder/ brake switch/throttle cables) Should be easy to get 7/8 stock aluminum bar.
I've never held the Rox Risers in my hands so I don't know for sure, but I can't imagine they will clear with stock cables/lines. I have to get my setup welded hopefully this weekend and I'll post up pics and info on how I did it. Wish me luck!! Wayne

 

[lawdog]

Stop teasing me and tell me more.... Pics for sure!

 

[racepro716]

Ok, here's some pics prior to welding. The parts aren't pretty and need a ton of finishing but.....here ya go. Wayne

Edit: Pic placement

 

[lawdog]

Interesting Wayne. You are making risers that are adjustable. My plan was to cut the bar and weld in a a riser similar to what ASB has for the 1125R.

 

[racepro716]

Oh, See my plan is to be able to go back and forth. One set of bars for everyday, one set for the long trips. My brother and I do a couple of 3 day 2000km trips a year. With these I should be able to switch back and forth in under 20 min. And they aren't adjustable, the slot is to find the "sweet spot" before welding. There is NO room for adjustment with this setup due to cable/line routing. Wayne

 

[FOURTYGRIT]

Nice job on the risers racepro, They look good. I'd like to see photos of the finished product. It will surprise me if you are able to raise your bars 1 3/4 inches without changing your front brake line. I just raised mine an inch and it's a tight squeeze. very tight. with little room for adjustment on the master cylinder. You've done a great job putting those together though. I'm eager to see photos...

Fourty...

 

[FOURTYGRIT]

Lawdog,

You should give Al a call at ASB. I know they have tried multiple different bar riser systems on the firebolt. He's got some great information. The lightning cable is roughly 2" longer than the firebolt cable. Al can tell you exactly how much longer. If you raise the bars more than an inch, a new front brake line will be necessary...(if you want to keep stock placement of the clutch cable and front brake line) I'm not sure about re-routing those, but with 1" rise mine is extremely tight. Let me know what you guys come up with.....looking forward to it.

Fourty...

 

[racepro716]

Fourty, The bars will rise 1 3/4 center to center without changing the brake line. You have to move the brake line outside of the forks although it is a bit of a stretch. Also as you mentioned, the clutch cable has to be re-routed at the front of the engine. Sorry I know pic's are taking a long time to show, I'm waiting on my welder bud. We'll get there though. Wayne

 

[FOURTYGRIT]

I understand what you're saying about moving the brake line. I don't understand what you mean by center to center. Looking forward to seeing the pics, might make more sense....

Fourty...

 

[lawdog]

I think he means the center of the bar coming off the riser to the center of where the new bar resides. So if you had 1 inch of rise and 1 inch of pullback then the center to center distance would be 1.41 inches.

(rise squared) X (run squared) = (center to center squared)

Al's bars at ASB have 1.1 inch rise and .43 pullback for a center to center of 1.18 inches.

 

[lawdog]

So I just got off the phone with Al at ASB. Nice guy by the way. He stated they are almost ready for the firbolt bars and hope to have them ready in a week or two. He stated watch the website as they will post when ready. He stated the price will be the same, probably be part #16503, and recommended the clutch cable for a lightning. He stated one firebolt owner reported his stock brake line was too short but everybody else has been able to use their stock brake line ok.

I asked him about the cable length and he stated the Lightning cables run about 3-4 inches longer then the firebolt and the ulysses run 6-7 inches longer then the firbolt.

 

[FOURTYGRIT]

Lawdog,

Glad you were able to talk to AL. If you order the bars I'd like to see picks of the install. Have fun with it. They make a difference.
By the way... I was able to keep the stock brake line, though it's a tight fit. I had to free up the coupling on the front fork to slide the cable through slightly, otherwise, no problem.

Fourty....