Ok just throwing it out there. Do you have the correct bleeders on the calipers?

 

Thought about that but then why is it firm when you loosen the caliper.......

 

They are the OEM harley banjo and bleeder. Throw all you want at this point...lol

 

Your drilling of the hose line ends has me suspicious !!!!!!

 

Are these for the brembos? NON BREMBOS ARE DIFFERENT.

 

Subscribed and curious.
No input just waiting to see end result/fix.

 

The ends being chrome were just under .400. Drilled them for brembo banjo.. Flushed them all out before assembly. They are good.

 

you said they were cvo takeoffs. why were they taken off? hate to say it, but you might have some bad parts.

 

So many folks have done this w/o issues, the problem is with the parts, your bike (e. g. ) damage to the forks), or poor installation.

I did mine a couple of years ago and started a thread about it--I son't recall anything about having to drill anything. I do recall buying a chrome banjo bolt used on the CVO master cylinder.

Hope you figure it out.

Carl

 

hey not sure if this helps but I encountered this problem when I put a 21 inch wheel on my sg.Same deal caliper pushed rotor, spongy lever.my advice is loosen the wheel and caliper,not sloppy loose.Spin the wheel hard a few times and lock up the brake.do this a fe w times and on the last time hold the brake and tighten everything back up starting with the wheel.1 other question did u mess with the triples at all? good luck