Banjo Bolt Problems.
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From: Limavady, N. Ireland
Banjo Bolt Problems.
Hi Guys,
I bought a new front master cylinder setup for my '89 electra glide classic a while back from USA (i live in N. Ireland), and got around to fitting it today. Problem is, the original banjo bolt at the master cylinder does not fit. The new cylinder seems to take a bigger bolt. Now, when i bought this, i was told it would be a straight fit (i specifically asked this question because of shipping costs to return!!) Is there a specific adaptor that i can buy to resolve the problem, or am i gonna have to go and buy new brake lines to fit? Cheers in advance.
Gee.
I bought a new front master cylinder setup for my '89 electra glide classic a while back from USA (i live in N. Ireland), and got around to fitting it today. Problem is, the original banjo bolt at the master cylinder does not fit. The new cylinder seems to take a bigger bolt. Now, when i bought this, i was told it would be a straight fit (i specifically asked this question because of shipping costs to return!!) Is there a specific adaptor that i can buy to resolve the problem, or am i gonna have to go and buy new brake lines to fit? Cheers in advance.
Gee.
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From: NW AR
If anyone has an adapter, it would be Pegasus, https://www.pegasusautoracing.com/home.asp
but I dunno in your case. I suspect you will probably wind up buying a new brake line. Pegasus could probably make that for you as well. I would think there would be a place on your side of the pond, though, but looking at their inventory should give you some ideas of what to look for.
but I dunno in your case. I suspect you will probably wind up buying a new brake line. Pegasus could probably make that for you as well. I would think there would be a place on your side of the pond, though, but looking at their inventory should give you some ideas of what to look for.
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From: Farmington ,MS
You may have the wrong mastercylinder for your application. In 89 single caliper brakes used 7/16-24 banjos...dual caliper set-ups used 3/8-24 at the MC. Somewhere around 2004 they changed to metric. So even if you get the hose hooked up, you probably have the wrong bore size so it won't perform correctly. 
Last edited by Tom84FXST; Mar 9, 2011 at 06:15 AM.
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From: Limavady, N. Ireland
You may have the wrong mastercylinder for your application. In 89 single caliper brakes used 7/16-24 banjos...dual caliper set-ups used 3/8-24 at the MC. Somewhere around 2004 they changed to metric. So even if you get the hose hooked up, you probably have the wrong bore size so it won't perform correctly.
Similar to this - http://www.chopperscycle.com/bagger/...sc-models.html
Now, what i don't get is why the fitting is different? When i bought the one i did, i specifically asked if it was a direct replacement, and was told yes!! So why if it's listed to fit dual disc '85 - '95 does it not fit dual disc?
Sorry for all the questions guys, but im snookered on this one!!
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Joined: May 2010
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From: Oregon
It doesn't sound like the ebay seller wants any returns and even if you could you'll want the problem resolved. If you don't own a tap & die set to determine thread size maybe you could bring it down to a friendly shop and have them check it for you. Once you know which one is correct, just order the correct banjo bolt if possible. Of course a replacement may not be chrome to match the housing.
I'd shoot the ebay seller a note since it is NOT a straight fit! Good luck on that though. Then I'd see if you could order the correct bolt from HD or elsewhere. That needs to be a solid fit or you might end up with tiny shreds of metal in the cylinder.
Good luck, I guess we got it a little easier on this side of the pond............
I'd shoot the ebay seller a note since it is NOT a straight fit! Good luck on that though. Then I'd see if you could order the correct bolt from HD or elsewhere. That needs to be a solid fit or you might end up with tiny shreds of metal in the cylinder.
Good luck, I guess we got it a little easier on this side of the pond............
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From: Limavady, N. Ireland
Right, so upon further investigation into this i have discovered that there are 2 different setups for the same thing!! (why though is beyond me!!).
setup 1 - 11/16 bore, 1985-1995 Dual Disc Models7/16-24 banjo bolt
setup 2 - 11/16 Bore, 1982-2002 Dual Disc Models3/8-24 banjo bolt
so, am i right in saying that if the bore is the same, all i have to do is buy the correct size banjo and brake lines and this will not effect the performance of the brakes?
setup 1 - 11/16 bore, 1985-1995 Dual Disc Models7/16-24 banjo bolt
setup 2 - 11/16 Bore, 1982-2002 Dual Disc Models3/8-24 banjo bolt
so, am i right in saying that if the bore is the same, all i have to do is buy the correct size banjo and brake lines and this will not effect the performance of the brakes?
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From: NW AR
If the bore is the same and the leverage is the same, then both units should function the same from a hydraulic standpoint.
Just a thought: If your new MC is 7/16 and your old one was 3/8 (6/16), and the only thing holding you up is that, take a sharp 7/16" drill bit (if they have those over there) and run it through your banjo bolt. Make sure both sides are nice and clean/flush, put new crush washers on and call it good. If you're going to replace the line anyway, you have nothing to lose.
Just a thought: If your new MC is 7/16 and your old one was 3/8 (6/16), and the only thing holding you up is that, take a sharp 7/16" drill bit (if they have those over there) and run it through your banjo bolt. Make sure both sides are nice and clean/flush, put new crush washers on and call it good. If you're going to replace the line anyway, you have nothing to lose.