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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #11  
Old 17th July 2019
Old Junk Old Junk is offline
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Sorry. Should have been more specific-

billscustomcycles.com

They're out of Bloomsburg, PA. Lots of nos Sportster stuff, some repop stuff of quality.
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  #12  
Old 17th July 2019
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Quote:
Originally Posted by Old Junk View Post
Sorry. Should have been more specific-

billscustomcycles.com

They're out of Bloomsburg, PA. Lots of nos Sportster stuff, some repop stuff of quality.
I tried there first. Emailed Bill. He's sorry; he doesn't have it.

I'll try Bill in Modesto next.

I'm also checking out the modular hose/line idea. JPCycles doesn't show what ends their stainless hoses have, just the length. They have the three-way splitter that bolts to the triple tree stem bottom, they're AN3. So I need hoses with AN3 female ends. There's no measurements given for the splitter so I'll have to order that first and then measure what length hoses I need. Probably take three separate order, over several weeks.

Last edited by ferretface; 18th July 2019 at 16:45..
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Old 18th July 2019
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I emailed JPCycles customer service as to what ends were on their V-Twin Power SS braided hoses (for example, their 18" 831-970); they say they are AN3. That's good; they will match up with the V-Twin 806-139 junction block directly.

But for the hose-to-caliper connection, I'll need an adapter to go from the female AN3 hose to whatever female threaded inlet is in the front calipers.

I don't want to take my front brakes apart in the middle of riding weather and be stuck waiting for mailed parts, and having to measure between shipments to determine the correct hose lengths I need. That's best done when the weather breaks and winter sets in.

But I can get some of the parts ready ahead of time, maybe all of them, as long as I know what I'm doing.

And there's the rub: I think I know what I need, but not the fitting sizes. For instance, is the HD master cylinder a 10mm or 12mm banjo fitting???

And more important for ordering lower hoses, what type fitting goes in the inlet hole in the caliper???

Edit: OK, I found out the 1983 caliper inlet port is 3/8" x 24 IFF, compatible with any NAPA steel universal brake line. Summit/Jegs/Earls all have AN3 to 3/8" x 24 adapters. so I'm good there (order for adapters going out today).

Edit2: I also ordered the Russell dual-disk junction block # 240-029 from JPCycles. It was cheaper than the V-Twin junction block.

Thank you for your help! I think I can do this...

It needs to look like this when done...
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Last edited by ferretface; 18th July 2019 at 18:35..
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  #14  
Old 19th July 2019
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...And after sifting through several catalogs, parts lists, and customer service techs, here's what I have come up with...(pic attached)...

I wasn't sure about the banjo fitting, but I was informed that it was correct for the HD master cylinder...

I've ordered the junction block, caliper adapters, and banjo fitting but not the three hoses. I need to measure the length of the junction block legs and order my hoses from there.

This would only be for a 1983 XLH with dual-disk front brakes, as far as I know...

Thank you all for the encouragement!
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  #15  
Old 19th July 2019
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Default Brake lines

I would suggest contacting Magnum. They were the only company that had lines for my '08 Roadster also with dual calipers.
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  #16  
Old 19th July 2019
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Default Here's the link.

https://www.magnumshielding.com/
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  #17  
Old 19th July 2019
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Quote:
Originally Posted by Tincan View Post
I would suggest contacting Magnum. They were the only company that had lines for my '08 Roadster also with dual calipers.
Nothing comes up for an 83 XL. Just clutch cables and ignition wires.
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Old 29th July 2019
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OK, I have all the parts for my 1983 XL(X) brake line assembly. My XLH has been 'upgraded' with several XLX parts including an XLX handlebar, albeit a chromed one.

I used a section of neoprene fuel line cable-tied to my OEM XLH brake lines to get my measurements (then stretched the line out straight to measure). The parts come from three different mfg's so I didn't list part numbers. No single vendor had everything.

I am somewhat disappointed that the hoses are so skinny compared to the OEM hoses.

I need to replace my speedometer at the same time I replace the brake lines, so I'll put that off till the weather worsens.

Thanks again for all the input!
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  #19  
Old 29th July 2019
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Default Brakeline size

The volume of brake fluid needed to actuate the calipers is very small. Most important is matching the proper master to the calipers used.
I think I mentioned before your calling Magnum Shielding. They have a solution for most anything.
I can't over state the quality of their products. I bought a replacement set for my '08 xl1200r when I upgraded to xr calipers.
I have a set of throttle cables and a new clutch cable from them. Just waiting for the heat to moderate in the early evening to do a oil change and swap in the new parts.
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  #20  
Old 30th July 2019
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Quote:
Originally Posted by Tincan View Post
The volume of brake fluid needed to actuate the calipers is very small. Most important is matching the proper master to the calipers used.
OEM master and calipers. I meant the OD of the lines/hoses. I like the look of the OEM hoses.

Quote:
I think I mentioned before your calling Magnum Shielding. They have a solution for most anything.
They say "Hi Rich, We're sorry but we do not carry that brake line. Thank you,"
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