Looking for some thoughts. I have a 16 Road King. I just put 12” KST bars on it and the right switch housing (front) broke where the bolt goes in. I ordered a new one and just installed it but the whole housing is loose - moves up and down around the bar 1/8 to 1/4”. Nothing else is broken or damaged and everything is tight. I can’t for the life of me figure out why. I did the bars myself and have done grips multiple times. No idea. Anyone ever seen this?

 

 

Got it. Still fairly new. Thanks BuzzCap7!

 

You have the small nub and groove on the switch housing/master cylinder properly seated together (highlighted spot on picture showing the groove)? If they bind, switch housing won't snug up properly.

 

Crotonrz thank you for the reply. All that lined up. I ended up wrapping the bar in that same area with double sided tape and that did the trick. The bars are perfect and very well made, it was a mystery. It was almost as though the bar was slightly thinner than stock by a hair but they are not because everything else fits. Thanks again.

 

Wrapping the bars with tape is not the answer.

You have either assembled it incorrectly, or there is a hardware issue.

 

I agree something was weird. But it’s just the switch cover and was seated correctly, just spun a little bit. Everything else on the bars are perfect. It’s tight now. When I get the energy and temperament to take it apart 17 more times I’ll go back in and look again. I am mechanically inclined, this one just got me

 

Is it possible there is a cable pinched in the housing? I have KST bars on three bikes, and never ran into an issue like that. If the housing was slightly loose on the bars, that would be one thing. But with 1/8 - 1/4" difference, that is something else. That is a lot of difference between the bar and housing.

 

Maybe I didn’t explain it very well. There’s no gap anywhere. The housing sits perfectly flush around the bars. It just spins around the bar up and down 1/8” or so. In other words it moves a little if I push the turn signal. Like it won’t tighten. Just a thin piece of tape around the bar on the inside edge fixed it. I was sure I did something wrong as the parts are all new but I couldn’t figure it out