Ironhead Help: 78-83' V-Twin Front Right Caliper and 74-77' Russell 51'' Brake Line

[Badblood]

Hi everyone,

I've tried contacting supply houses to resolve this issue, but I need help from the real experts...
I bought a VTwin 78-83 Front Right Caliper for my 1980 Harley XLS1000, in addition, I bought the 74-77 Russell 51'' Stainless Steel Front Brake Hose (also distributed by VTwin) because I have extended forks and I'm running a single caliper.
Here's the problem: The brake hose 3/8-24 threaded inverted flare fitting does not thread all the way into the caliper's housing to create a tight connection with the flare butted all the way against the caliper's cavity. Instead, it threads the full length of the fitting, but the threaded cavity port is longer in thread length/depth than the 3/8-24 fitting. This allows me to pull up and down on the flare, with about a 1/4'' movement.
Now I understand I bought a 51'' 74-77' brake hose, BUT, Russell's brake hose that is listed for my bike also has 3/8-24 fittings on both ends. I was told from the horses mouth (Russell) that an AN3 and a 3/8-24 fitting are the same thing, and that all their brake lines that have a 3/8-24 fitting are threaded to the same length. They do not have a brake line with a longer thread on other brake hoses to fit different caliper's thread cavity length.
I also spoke with a shop that called VTwin for me since I'm not a dealer, they confirmed for me that this Caliper does take a 3/8-24 fitting, but V-Twin recommends I purchase the brake lines that are for this bike. However, if those brake lines also have a 3/8-24 fitting that is universal in thread length, than that still does not solve my conundrum.
So what do I do?? I want to use this hose, and I want to use this new brake caliper!!! Am I missing something here? Does a 1980 Harley XLH1000 front caliper have a longer thread depth than a 1974-77, and thus needs a very special brake line that has a 3/8-24 fitting which is a ~1/4'' longer in thread length? Or has VTwin/Taiwan xxxxed up their manufacturing and over-bored this particular caliper I bought from JPCycles? The bore is the same length/depth as the bleeder port's depth/length.
Here is the caliper: https://www.jpcycles.com/product/v-t...ku_id=10243699
Here is the brake-line: http://ps.russellperformance.com/pow...s/harley.shtml
Also fun fact, Russell's website does not list a brake hose for my 1980 XL anymore, but the VTwin website does show a few, which VTwin says is cross-compatible with the FX: https://www2.vtwinmfg.com/catalog/ca...2198/?cat=2199
https://www2.vtwinmfg.com/stainless-...rake-hose.html
https://www2.vtwinmfg.com/stainless-...rake-hose.html

Am I missing something here? The Sportsterpedia page states that a 74-77 front caliper takes an AN3 inverted flare, and a 78-83 takes a 3/8''-24: http://sportsterpedia.com/doku.php/techtalk:ih:wheels02

Thank you! I'm losing my head over this and I do not want to return/buy another brake line/warranty this caliper. If someone has a solution available like a strange adapter I could use, I'd greatly welcome it. PS calling Russell took 45min on hold, calling Vtwin is a nightmare they won't honor your call, and JPCycles doesn't have all the data.

[Badblood]

I think I might have figured it out... just finally looked at my damn manual. Shows in Figure 2-43 a brake hose seat, labelled #3. Could that possibly be the issue? I don't think have this seat installed in the caliper, might this cause the 1/4'' play up and down I'm experiencing? Will post a picture... Thanks - Youngblood

[JB in NC]

I think you have a bad caliper, and that seat being missing was my first thought. Send it back.

Jim

[wiltybob]

have you checked whether the brake line fitting has a concave or convex end. pretty sure it needs to be concave but if it isnt its convex. no i'm sure it is concave. just got to look into the caliper and if its raised you need a concave but if its 'recessed' you need a convex.

if that is the problem its easy enough to get an adapter if the end fitting on the line cant be removed

[BigMek]

Check if there is actually an inverted flare seat in the caliper. I remember having this same problem with V-Twin calipers and it was because they didn't have a seat, just a threaded hole.

Whether or not you have the seat it's an easy fix - you just need a male-to-female adapter like this one: https://www.russellperformance.com/3...ir-641291.html

Make sure you get crush washers too. Since the adapter won't be pressed against anything it has no sealing mechanism. Example: https://www.russellperformance.com/1...ck-683980.html

Edit: I would also suggest adding some Pneumatic/Hydraulic sealant to the male adapter threads so the fitting stays put. Loctite 545 or Permatex 54540.

[wiltybob]

think thats what i said. inverted = concave

[ryder rick]

VTwin is notorious for shipping defective parts.

and have a poor rep for cust service

[JB in NC]

Originally Posted by BigMek

Check if there is actually an inverted flare seat in the caliper. I remember having this same problem with V-Twin calipers and it was because they didn't have a seat, just a threaded hole.

Whether or not you have the seat it's an easy fix - you just need a male-to-female adapter like this one: https://www.russellperformance.com/3...ir-641291.html

Make sure you get crush washers too. Since the adapter won't be pressed against anything it has no sealing mechanism. Example: https://www.russellperformance.com/1...ck-683980.html

Edit: I would also suggest adding some Pneumatic/Hydraulic sealant to the male adapter threads so the fitting stays put. Loctite 545 or Permatex 54540.

Or maybe use 3/8 banjo fittings like the later calipers use.

Jim

[ryder rick]

If it does not have a seat you need to install an adapter from 1/8" pipe to 3/16 tube.
https://www.amazon.com/Brake-Adapter.../dp/B01KNGW04E

It must have a machined flat surface for a banjo to seal.

Is this a -74 (pie)caliper (I'm guessing)or an -84 or one side of a dual disc caliper (10" or 11" type)?

edit - Looking at your link that is a single caliper from a 10" dual disc set and should take a 3/16 inverted flare.
Unless there is a machined surface around the hole for a Banjo.

[Badblood]

Hey everyone, thank you for all the responses, I ended up buying the seat… funny I found one on EBay that was nos jpcycles, I don’t believe they sell it anymore.
At the moment I have the seat installed, brake line is now tightly secured, I’ll let you guys know once I get the dot 5 fluid in there and bleed it if there’s still an issue.