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[texguy75]

I've found numerous threads on the chubby handlebars, but none that address my install problem. 

My Bike. 2006 FLHTCUSE Chocolate/Candy Green
Install problems:
1.  Left, clutch side grip will not slide all the way on. I've tried everything, but always have a 3/8" gap.  I have the Stock heated grips.
2.  All cables fit except the front brake. The stock cable has press fitted ends. Is there any way to splice into the upper cable to extend it or do I have to buy the whole 3 piece brake line? 

Any thoughts, fixes, suggestions?  All will be greatly appreciated!!!!

[mattm]

1.  Can you be more specific about where the gap is?  Are you using the stock grip?  Are you certain the grip is bottoming out on the end of the bar?

2.  You will need to replace the entire front brake line assembly, you can,t lengthen that one part.  Jim (HD-dude) can help you out with the correct replacement.  PM or call him.

3.  Did you have the 2 piece handle bar top clamp?  If so,be sure to replace it with the correct 1 piece.

Good luck.

[Widows Son]

Just had the Chubby installed on my bike last week by a bike shop. I had the same gap issue on my left grip (non heated). It wasn't as sever as yours - 2 to 3 mild. The shop had to grind the end slightly. Came out great.

I had all new brake lines installed (stainless braid). Since my bike is ABS equipped, the front brake cable is two piece (to the ABS module and then from there to the front calipers). IMO: don't compromise on your brake system's integrity. Go with a new cable from stem to stern. Any splices pose as a potential failure point...the brake system is not one I'd like to have that risk. Again, my very humble opinion.

[mjb765]

If his bike had ABS--I don't think it did in 2006--he would need a new line from handlebar master cyl to module. If he does not have ABS, he would need a new lione from the handlebar to the front "T" block. He does not need the 2 lines down to the calipers unless he is switching to a different type of line...for ex. non-braided to braided just so they all match.

[mattm]

2006 is non-abs.  The factory front brake assembly (3 hoses with center block) is all one piece.  You will need to replace the whole assembly.

[mjb765]

2006 is non-abs.  The factory front brake assembly (3 hoses with center block) is all one piece.  You will need to replace the whole assembly.

The non abs part is what I thought....didn't know that was all 1 piece.....I stand corrected

[texguy75]

My bike is non-abs and the front brake setup is all one piece with press fitted ends.

Y'all are right and I found a local shop that made me an entire new 3 line front brake assembly with the top line 3" over stock.  So brake line problem fixed.

I was thinking that cutting and grinding my be required on the left handlebar so the grip will fit. The grip is the stock "stealth" line heated grip that came on the bike. The gap I'm referring to is right of the clutch handlebar bracket to the upset on the chubby bars where they go from 1" to 1 1/4". The distance is 1/4".

So cut a 1/4" off the handlebar at the end where the left grip slides on?

Thanks again for all your help!

[Midnight Rider]

My bike is non-abs and the front brake setup is all one piece with press fitted ends.

Y'all are right and I found a local shop that made me an entire new 3 line front brake assembly with the top line 3" over stock.  So brake line problem fixed.

I was thinking that cutting and grinding my be required on the left handlebar so the grip will fit. The grip is the stock "stealth" line heated grip that came on the bike. The gap I'm referring to is right of the clutch handlebar bracket to the upset on the chubby bars where they go from 1" to 1 1/4". The distance is 1/4".

So cut a 1/4" off the handlebar at the end where the left grip slides on?

Thanks again for all your help!

While you're in there, I'd spend the few extra bucks and put the Heat Demon heaters for the grips...you'll have to buy the non heated Stealth Grips to go back on, but you'll never have to worry about the grips not working right (heaters).  MOst here have had issues with the HD heated grips

[hd-dude]

The old style bars did not have a tapered end on the left side. This taper is required for bikes with then Hydro Clutch. I have done many installs and not had a fitment issue with the later style 575's. These have been in production for a few years now....The brake line and throttle/idle cables will need to be repalced. I know you mentioned that then throttle idle fit but they will bind.

[texguy75]

The old style bars did not have a tapered end on the left side. This taper is required for bikes with then Hydro Clutch. I have done many installs and not had a fitment issue with the later style 575's. These have been in production for a few years now....The brake line and throttle/idle cables will need to be repalced. I know you mentioned that then throttle idle fit but they will bind.

Thanks for the input. I will look into the demon grips.

So, did I accidentally get an old style bar without the tapered end or because I specified my year and make sent me bars that were originally made for my 2006 FLHTCUSE? 

Yeah I was debating on the throttle/idle cables. Thanks for making my decision easy. Changing them out too.

What a day!  Handlebars, custom cables, swapped air temp for oil temp in fairing, installed isimple iPhone aux cable, and changed a burnt out tail light!!!!!