Need Help, Handlebar Install

[04newhog]

I'm currently installing 12" Apehangers on my 2004 XL 1200 Roadster. I got the wiring all finished and ran inside bars. I ordered Russell braided Cables Throttle, Idle and Clutch, they all fit fine. Now get this I go to local shop pick up cables and still need brake line. He sells me everything I need, I get home and find out 12mm Banjo won't hook up to Master Cylinder on bars. They changed the size on Banjo Bolt and fitting on 04's. It looks like a 14 mm bolt and fitting. What do I do any suggestions or has anyone else run into this?

[maddog]

I'm currently installing 12" Apehangers on my 2004 XL 1200 Roadster. I got the wiring all finished and ran inside bars. I ordered Russell braided Cables Throttle, Idle and Clutch, they all fit fine. Now get this I go to local shop pick up cables and still need brake line. He sells me everything I need, I get home and find out 12mm Bango won't hook up to Master Cylinder on bars. They changed the size on Bango Bolt and fitting on 04's. It looks like a 14 mm bolt and fitting. What do I do any suggestions or has anyone else run into this?

Return it and get the braided one from Harley. They'll have the right size bolts.

[TechRep]

I read somewhere (maybe here) about this issue, and I think they said they bored (drilled out) the bango. Haven't seen it or tried it. You might try a search to find the forum.

[04newhog]

I already talked to local Harley dealer. They do not yet make an extended brake line and get this....they weren't even aware the banjo bolt and fitting size had changed....until I went in and they looked it up.

[TechRep]

04newhog... Just so you know, I have not done this, and would not recommend it without experiencing it for myself. I just wanted you to know that I had read that it was done at some point by someone.

[barry1967]

Yep, 04s have 14mm bolts, rendering everything that fit 03 earlier useless :rolleyes: . Leave it to the MoCo for job security or should it be new product security :frownthre

[04newhog]

I drilled it out, Chipped the chrome a little on flat side where washer goes, so I filed both sides flat. Haven't filled with fluid yet and bled brakes, but I think it's going to work. Thanks TechRep

[Gone]

Bango? -- ;)

[TechRep]

Bango? -- ;)


No wonder I could never learn to play that damn thing... I can't even spell it!!!! :D

[sportsterrific]

The bolt is the shape of a 'BANJO'. I dunno what the heck a 'Bango' is although it sounds like fun!

[04newhog]

Guess I flunked your spelling test, or was it typing? Actually the fitting is the shape of a banjo. The "BOLT" is the shape of a "BOLT".

[LVBOATDOC]

This is a little late but I had the same problem when I put on aftermarket chrome control on my bars. The brake cylinder had a bigger banjo bolt than my old one, so I did what your doing and drilled it out. Works just fine, no leaks been on for 6 months.