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Sportster Motorcycle General Discussion and Problems For discussing problems about your Sportster motorcycle that don't fit anywhere else.

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  #1  
Old 11th February 2010
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Default iron 883 front caliper banjo bolt size

Please help. I've looked everywhere and can't find this info. What is the size of the stock front caliper banjo bolt for an 09 iron 883?

I am installing some joker machine jx controls and they take a 10mm banjo bolt at the MC. I need to order some new brake lines to get the length I need and when I check the banjo bolt size at the front caliper, it seemed to be a 12 mm. Everything I have read said it should be a 10mm. They way I confirmed that it wasn't a 10mm was by seeing if the caliper bolt would fit in the 10mm MC - and it didn't. Hope this makes sense.

So at the moment it seems I need to order a 42" line with a 10mm straight banjo at the MC and a 12mm 40 degree bend at the caliper (I think it should be a 45 degree bend but cyclebrakes.com only offers a 40 degree or a 90 degree bend). Apparently this is just a weird combo so I want to make sure it will fit before purchasing.
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  #2  
Old 11th February 2010
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Quote:
Originally Posted by chopfury View Post
Please help. I've looked everywhere and can't find this info. What is the size of the stock front caliper banjo bolt for an 09 iron 883?

I am installing some joker machine jx controls and they take a 10mm banjo bolt at the MC. I need to order some new brake lines to get the length I need and when I check the banjo bolt size at the front caliper, it seemed to be a 12 mm. Everything I have read said it should be a 10mm. They way I confirmed that it wasn't a 10mm was by seeing if the caliper bolt would fit in the 10mm MC - and it didn't. Hope this makes sense.

So at the moment it seems I need to order a 42" line with a 10mm straight banjo at the MC and a 12mm 40 degree bend at the caliper (I think it should be a 45 degree bend but cyclebrakes.com only offers a 40 degree or a 90 degree bend). Apparently this is just a weird combo so I want to make sure it will fit before purchasing.
Does the caliper bolt fit inside the banjo fitting for the MC ? I think they may be 10mm, but a different thread pitch. if it doesn't fit, instead of 12mm try 7/16ths.. May be a more common combination.
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  #3  
Old 11th February 2010
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12mm 04-up 883
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Old 12th February 2010
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Quote:
Originally Posted by ReddTigger View Post
Does the caliper bolt fit inside the banjo fitting for the MC ?....
I'll try it when I get home. thanks.

Quote:
Originally Posted by billy bob View Post
12mm 04-up 883
So you're saying it's 12mm for the caliper banjo bolt as well as the MC?
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Old 12th February 2010
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Got this out of the Goodridge catalog:

Harley Davidson
Up to 2004 Single front disc Harleys always use a 3/8 x 24 bolts for the caliper
and a 7/16 x 24 for the Master Cylinder. All Harleys with a dual disc front use
3/8 x 24 throughout the bike. From 2004 Harley use a combination of 10 x 1mm
and 12 x 1.5mm



Still doesn't help but at least it is something to start with.
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  #6  
Old 12th February 2010
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Sorry, one more post: the powersport rider.com catalog says that all 04-09 XL single front brake systems use 12mm x 1.25 for both the MC and the caliper. Looks like I was right, but would love to hear someone with more experience comment.
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  #7  
Old 12th February 2010
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my answer was in response to the question you initially asked in your post. (banjo bolt size in a stock front caliper for 09 iron 883) - 12 mm

I looked at the joker machine site and I think you have it right. 42" brake line, 1-40 deg. 12mm banjo fitting, 1-12mm banjo bolt (caliper)

1- straight 10 mm banjo fitting, and 1- 10mm banjo bolt (joker machine mast. cyl.)
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Old 12th February 2010
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great, thanks a lot Billy!
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Old 12th February 2010
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By the way, nice looking hand controls. Good luck with the install.
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Old 3rd March 2010
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So in case anyone checks this thread out: the banjo bolt for both the caliper and the MC is 10mm...anyone need a custom magnum break line with 12mms on one end and 10mms on the other? Black pearl, 42".

Oh well lessoned learned.
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