How do I change extend the brake line from stock handle bars to 14 inch bars on an 883r? Can I just extend the first line before the splitter?

handle bar post is held in the head unit by a taper block and a split in the bar post
undo the central bolt about a /14 inch and tap the bolt down . this releases the clamp action and you will be able to lift the bar section up .
centre the bars to straight ahead and re-tension the centre bolt

Like this or pretty close.

1. Cock brake while expanding chain brake binder by pulling brake handle towards left-hand (wrap-around) handle grip, hard, until it locks in place.



2. Loosen 2 brake-asssembly-and- bar retaining nuts but do not remove yet.



3. Unscrew (turn CCW) bar adjustment screw on front face of unit in order to shorten bar and slacken saw chain.



4. Slip chain off bar over bar tip and towards inward side of bar.



5. Remove two nuts loosened in step 2 and pull brake assembly and bar straight out and off bar mounting studs.



6. While rotating clutch/brake-drum, maneuver saw chain off sprocket and around drum perimeter to remove from saw.



7. Repeat/reverse steps 6 thru 1 in that order to reassemble.

You will need to make these lines up from straight stock And bend and double flare the ends to handle the pressure, this requires of course special tools and very special skills. You can't buy already make up replacement brake lines.

Did this happens before to go for extended cable??Then your new cable have too much curve so it cannot pull easily.

Better to be too long than too short. Use the short lines as a guide and measure the extra length you need. Reorder the correct size. If the lines are too short the first time the front end fully extends you will tear the end off of the line and have no brakes. Extending the line is a bad option and tying down the front end will change handling and be more expensive than just ordering another set of hoses.

You need to know how much taller your new bars are over you old one. If they're 4 inches higher, you need a 4 inch over length brake line. Now, if your brake line from the master cylinder on the handlebars goes to a "junction tee" located underneath the lower triple tree, you can simple replace the upper half. Usually, you don't see this unless the bike is equipped with dual discs brakes.

If you brake line is one piece all the way down to the caliper, you must replace the entire brake line. The best way to do any of this is to put the new handlebars on the bike, install the front master cylinder and use a piece of stiff wire and run a "fake" brake line down to the caliper. Then, measure the length of the "fake" brake line to get the proper length that you need.

Good Luck
Steve

Hi MonkeyManTim

Firstly, remove the centre lock nut on the stem. This loosens the stem/headset. Pull the handlebars up and rest them next to the front wheel, make sure the brake cables aren't being stretched too much.

You'll see there is a locknut on the headset (at the top of the frame/top tube where you pulled the stem from) and loosen this (might need a massive spanner!).

Pull offthe toppart of the headset, ball races and lower part. Replace with the gyro bottom and top parts. Grease the ball bearing if they aren't already!

Slide it together, fit the stem and you'll notice the brake lines that come with it. Undo the rear brake, run the splitter cable from the front lever to the top half of the gyro, same with the bottom half. I found putting some padded stickytape on the bars helped here as the splitter cable would 'ting' off the bars.

Undo the front brake and run it through the stem hole, through the forks and cable tie it to one fork leg.

Test the brakes, adjust where necessary and on you go pulling bar-spins for fun. Please don't land a jump with the bars half spun, it hurts....a lot!!

hi dennis. firstly there ain't no extra inside the headlight. it's very tight in there. remove the light using small phillips screws on either side. (dang what a mess)
you can slip off your old handlebar controls no problem, loosen them up before removing the riser clamps, then you can easily slip them off as you can move the bars to do so. slip controls on new bars and try mounting, if wires are too tight you will have to find them in the headlight and extend them.

I added a 2 inch riser to my dyna and didnt have to replace any cables, so - to answer your question, not always. There is plenty of wiggle room, however, if there is gonna be more difference that about 2 inches, replacement will be required. ADJUSTMENT WILL DEFINITELY be needed. And no, its not difficult, when u have the bars off, its nearly 1/2 done anyway

fuse their under the seat and their marked good luck