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Author Topic: Ape hanger installation (Carlini 16" 1.5" diameter)  (Read 684 times)

Chris Penner

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Ape hanger installation (Carlini 16" 1.5" diameter)
« on: March 13, 2017, 11:49:49 PM »
Well guys I know stratoliner Bob did a post about this a couple years back but that being said after doing this and coming out the other end I think there where a few pieces missing and a real under playing of the work involved. So here it goes. If you need any clarifications or need some guidance just ask. If you need an immediate response email me direct at chris.penner@gmail.com

So this wasn't the cheap option or the easiest option to get apes on the strat but it is by far the coolest. I will attach a few pictures to show what was going on.

Parts to install:
1x Carlini Gangster 16" apes 1.5" diameter
1x Carlini El Presidente 1.5" Risers
1x Lengthened Brake line (3 line kit from Pacific coast star)
1x Lengthened Clutch line
1x Lengthened Set of Throttle Cables
1x Avon Grips
1x Brakeaway throttle lock

Step 1: Disassembly: this includes pulling head light apart (take pictures just incase you forget how it all goes back together) unhook all the wires, drain front brake MC and clutch MC. I used a syringe with some bleeder hose and sucked it out cost 3 bucks to make. Unhook front brake MC. Plug MC hole with something so fluid doesn't leak out everywhere. Then unhook clutch MC and level loose making sure not to spill brake fluid every where. Now the fun part. I have a V&H 2-1 exhaust so to make way for the new extended clutch line I had to remove the exhaust to remove clutch hard line so I could replace whole line with new extended one (first unforeseen project) not hard but you need at least one set of hands to help. Then remove bars and set aside, remove risers and get ready for the fun to begin.

Step 2: Point of no return. This is where you get your step drill bit out and cutting fluid and start to drill out the riser bushing to 1/2". Use a step bit to start them so you have a good shot at being square heading into the bushing then switch to 1/2" drill bit and proceed. Made it through with a little patience.

Step 3: Test fit new risers only to discover that the risers jam into the top chrome cover piece of the triple trees and prevent the riser for seating right against the bushing. (next unforeseen) Easy fix 3 grade 8 washers to match my 3" 1/2 - 13 grade 8 bolts. per side painted black so they disappear in the cavity. Test fit bars to see how it looks. AWESOME.

Step 4:Remove wires and MCs from old bars set bars and MCs aside. Start the long painful task of lengthening all the wires in the harnesses. We cut wires staggered near the end add on to the switch side labeled all wires and shrink wrapped them and left the 4 big connectors off until after we ran wires through and then solder them on after so we didn't have to pull the pins out of the connectors.

Step 5: Before running wires we immediately realized the holes to run the wires internally where not sufficient in size so back to the step drill bit to in large the bottom hole where the wires exit the bars and we also had to open up the grip side holes with a 1/2" drill bit to get the wires in along with giving us the clearance to fill the sharp edges down so we wouldn't shred the wires as we pulled them through. File file file thats the name of the game.

Step 6: Run new wires through pretty straight forward there and then solder on the big connectors.

Step 7: Moment of truth rough mount bars into risers then remove to tighten down since access to rear riser bolts are unaccessable due to the top chrome cover piece again. Then re attached and red lock tight those suckers on there (at the recommendation for Chucky from Barons custom) crank them down. Now hook up all wires and cross fingers that all your solders are good start the bike and try everything...good to go.

Step 8: Rough mount brake MC and Clutch MC (don't worry Carlini says the bars aren't compatible with hydraulic clutches...turn out they are just fine at least with the strats). Then get those set and then figure out where your switch boxes need to be to line up with everything and find a way to mark the locating pin on the switch boxes to drill a 1/4" (I think just check your stock bars for hole size) (this was the next unforeseen) and don't hit your switch box wires as you drill through. I used a long fill inserted from the bar end to hold wires down and out of the way (had a friend do this actually). Then close it all up.

Step 9: Run new throttle cables. This requires removing the tank (swinging it out of the way in the case to speed things along). Remove little chrome side cover to allow better access to throttle cables. Switch them over. You will have to loosen a few things to get old cables out but not a big deal. Run new cables and don't forget to screw in your push cable in first before you pass it through other wise you won't get it in. Then button it up adjust throttle cables and grip and put tank back on.

Step 10: Hook up clutch line to MC. Hook up Brake line to MC (only to find out the one sent is 2" too short says +9 turn out its only a +7 hahaha. wait for new line) Bleed brake and clutch. All finished project just put on left grip.

Step 11: Put on brake away throttle lock. I haven't made it this far since I am currently waiting for the new brake line to show up. But this will be easy.

Pictures files too big to post more.

New bars look sweet I'll attach a couple more photos once the weather stops raining and I get the lines bleed and bike washed up. Hope this brings some insight. Not super difficult just need a couple extra hands, cold beer and time.


« Last Edit: April 30, 2017, 10:25:37 PM by Chris Penner »




drmikeyd

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Re: Ape hanger installation (Carlini 16" 1.5' diameter)
« Reply #1 on: March 14, 2017, 12:14:43 PM »
Great post.  And thanks for the detailed description!
Freedom True Duals, PCV, Purple Filter. Just trying to keep up with the wife on her Raider...

Chris Penner

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Re: Ape hanger installation (Carlini 16" 1.5' diameter)
« Reply #2 on: March 14, 2017, 02:59:17 PM »
Yeah no problem.

sink

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Re: Ape hanger installation (Carlini 16" 1.5' diameter)
« Reply #3 on: March 16, 2017, 08:40:51 AM »
This is great information, so I'm making it a sticky.

Chris Penner

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Re: Ape hanger installation (Carlini 16" 1.5' diameter)
« Reply #4 on: March 16, 2017, 03:12:00 PM »
Oh yeah...Got stickey'd... Thanks Sink. Hope the info can be of some use to others too.
« Last Edit: March 16, 2017, 03:14:28 PM by Chris Penner »

BigFuji

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Re: Ape hanger installation (Carlini 16" 1.5" diameter)
« Reply #5 on: May 23, 2017, 11:07:54 AM »
I did mine winter of 2016. Love the look and all that work is so worth it. You did a nice write up. I changed the fluid in my forks and replaced the front wheel bearings while I had it apart. It ended up being about $1100 for me. Where did yours come in at? I find them very comfortable on long rides. First long trip was Michigan to Arkansas last summer. Loved every minute.

BigFuji
BigFuji
Sometime you gotta take the log to the beaver

Chris Penner

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Re: Ape hanger installation (Carlini 16" 1.5" diameter)
« Reply #6 on: December 20, 2017, 07:10:23 PM »
Sorry for the delay in reply. I don't even know what the cost was. But it wasn't cheap. Since I needed bigger risers to fit the 1.5" bars that cost me more and since I really want that gangster ape look no one else has that bar so I had to get a carlini bar which comes at a premium and the riser I got from them too. I knew what I wanted it to look like and just spent the money I am sure I wasn't far of of the $1100 dollar mark. But I also put a throttle lock and new grips on too.  They are awesome had a whole season on riding on them including a 2500 km trip over 4 days. Never any shoulder trouble or hand issues that stemmed for the bars.

Cheers.