Swapping handlebars on a Sportster should be straightforward. Too often it isn't — wrong cable lengths, a brake line that's two inches short, and a wiring harness that's in the way. Burly Brand built this 8-inch Control Kit specifically to solve that. Everything you need to run 8-inch tall bars on your XL Sportster is in one box, sized correctly for your year and model from the start. No hunting down individual cables. No adapters. No surprises mid-install.
What's in the Kit
Every component has been spec'd to work together on the correct model year:
Black vinyl clutch cable — 54-1/2" housing, 2-3/4" travel, with 2 brass barrels and 1 black plastic barrel
Black vinyl throttle cable — 26" housing, 4-3/4" travel
Black vinyl idle cable — 26-1/2" housing, 4-1/2" travel
24" black vinyl brake line with 3/8"/10mm 20-degree banjo fitting and 3/8"-24 inverted flare
17-3/4" black vinyl brake line with 3/8"/10mm 90-degree banjo fitting and female AN#3
Junction block with two AN#3 fittings
Four 3/8"/10mm copper crush washers
Two banjo bolts
Full instructions included
The brake lines use a PTFE inner liner with a heavy-duty stainless steel outer braid — built for durability and proper brake feel, not just to make the fitment work.
Compatibility
This kit fits the following ABS-equipped Harley-Davidson XL Sportster models:
2016–2022 XL1200X Forty-Eight
2018–2019 XL1200XS Forty-Eight Special
2018–2021 XL1200NS Iron 1200
2016–2019 XL1200C Sportster 1200 Custom
2016–2017 XL1200T SuperLow 1200T
2016 XL1200V Seventy-Two
2016–2022 XL883N Iron 883
2016–2019 XL883L SuperLow
Confirm your year and model before ordering — Burly Brand makes separate kits for non-ABS models and for different bar heights. This one is specifically engineered for 8-inch tall bars with ABS.
Installation
This is a straightforward swap for anyone comfortable working on their own bike. The kit includes step-by-step instructions, and every cable and line is pre-sized — you're not cutting or fabricating anything. A few things worth knowing before you start: bleed the brake system after swapping the brake line, torque the banjo bolts to spec, and always use the fresh copper crush washers included in the kit. The junction block is already configured for ABS models. For most riders, this is a one-afternoon job with basic hand tools.
Who This Is For
Sportster riders putting on scrambler-style or tracker-style 8-inch handlebars who don't want to source cables individually or guess at sizing. Also useful for anyone returning from a taller bar setup back to something closer to stock height and needing properly routed lines for the ABS system. If your bike is in the fitment list above and you're running 8-inch tall bars, this kit handles everything in one shot.
Key Benefit
The brake lines are built with a PTFE-lined inner core and stainless steel outer braid. That matters because you get accurate brake feel, resistance to expansion under pressure, and protection against abrasion — all without upgrading to fully custom hydraulic lines. The PTFE lining also resists moisture absorption over time, which keeps brake fluid performance consistent longer. Combined with the correct-length throttle, idle, and clutch cables for your specific model year, this kit removes any compromise from the build.
Kit Specifications at a Glance
Clutch cable: 54-1/2" housing | 2-3/4" travel
Throttle cable: 26" housing | 4-3/4" travel
Idle cable: 26-1/2" housing | 4-1/2" travel
Brake line (main): 24" with 20-degree banjo and inverted flare
Brake line (secondary): 17-3/4" with 90-degree banjo and female AN#3
Brake line construction: PTFE inner liner, stainless steel outer braid
Origin: Made in the U.S.A.
Finish: Black vinyl
FAQs
Does this kit work with both ABS and non-ABS Sportsters? No. This specific kit (B30-1271) is engineered for ABS models only. Burly Brand makes separate kits for non-ABS XL Sportsters. Check the fitment list and your bike's configuration before ordering. Will this fit my Iron 883 or Iron 1200? Yes, provided it's an ABS model in the correct year range. The Iron 883 (XL883N) is covered from 2016–2022, and the Iron 1200 (XL1200NS) from 2018–2021. Do I need to buy anything else to complete the install? The kit includes all cables, brake lines, the junction block, copper crush washers, banjo bolts, and instructions. You'll need standard hand tools and fresh DOT 4 brake fluid for bleeding the brake system after the line swap. What bar height is this kit designed for? It's specifically engineered for 8-inch tall handlebars — scrambler bars, tracker bars, or any bar in that height range. Using it with a significantly different bar height may result in cables that are too long or routed incorrectly. My Forty-Eight has ABS — is it in the fitment list? Yes. The XL1200X Forty-Eight with ABS from 2016–2022 is a confirmed fit. The XL1200XS Forty-Eight Special from 2018–2019 is also covered. How long does the install take for a home mechanic? Most riders finish in two to four hours. The instructions are clear, and nothing needs to be cut or modified. The brake bleed is the step that takes the most patience, but it's not complicated. Why use a Burly kit instead of sourcing cables separately? Sourcing cables individually means measuring, cross-referencing routing for your specific ABS configuration, and hoping everything arrives at the correct length. Burly has already done that work — the cables and lines in this kit are matched to your exact model year and bar height, with verified fitment and matching hardware included.
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