CHROME BANJO BOLT KIT
J043662008-07-30
GENERAL
Kit Number
41843-08
Models
For model fitment information, see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
For ABS Models
WARNING
The rider's safety depends upon the correct installation of this kit. Dealer installation is required for vehicles equipped with ABS brakes. Proper installation of this kit requires the use of special tools available only through a Harley-Davidson Dealer. An improperly serviced brake system can adversely affect brake performance, which could result in death or serious injury. (00578b)
For Non-ABS Models
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
Additional Parts Required
NOTE
This instruction sheet references service manual information. A service manual is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 5 and Table 1.
INSTALLATION
Prepare the Motorcycle for Service
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
  1. Disconnect the negative (-) battery cable following the instructions in the service manual.
Front Brake Caliper and Master Cylinder
NOTE
Put a container under caliper to catch brake fluid that may flow from the brake line when removing banjo bolt.
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240d)
1.
See Figure 1. Remove rubber cap (4).
2.
Remove the banjo bolt and gaskets from the front brake line from one front caliper. Discard gaskets and banjo bolt.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a)
3.
Lubricate new gaskets with appropriate clean brake fluid.
4.
Install new gaskets (2), brake line and banjo bolt/bleeder screw (3) onto the caliper in the order shown in Figure 1. Tighten banjo bolt to 17–20 N·m (12.5–14.5 ft-lbs).
5.
Repeat Steps 1-4 for opposite front caliper.
6.
Remove the banjo bolt (1) and gaskets (2) to detach front brake line from master cylinder. Discard gaskets and banjo bolt.
7.
Lubricate new gaskets with appropriate clean brake fluid.
8.
Install new gaskets (2), brake line and banjo bolt (1) onto the reservoir in the order shown in Figure 1. Tighten banjo bolt to 17–20 N·m (12.5–14.5 ft-lbs).
9.
Install rubber cap.
1Banjo bolt
2Brake line gasket (6)
3Banjo bolt/bleeder screw assembly (2)
4Rubber cap (2)
Figure 1. Front Brake Line and Master Cylinder
Rear Brake Caliper and Master Cylinder - All Models Except VRSC
NOTICE
Do not allow dirt or debris to enter the master cylinder reservoir. Dirt or debris in the reservoir can cause improper operation and equipment damage. (00205c)
1.
Remove the saddlebag, if equipped.
NOTE
Put a container under caliper to catch brake fluid that may flow from brake line when removing banjo bolt.
2.
See Figure 2. Remove banjo bolt and two gaskets. Discard gaskets and banjo bolt.
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a)
3.
Lubricate new gaskets with appropriate clean brake fluid.
4.
Install new gaskets, brake line and banjo bolt onto the caliper. Tighten banjo bolt to 17–20 N·m (12.5–14.5 ft-lbs).
5.
Install saddlebag, if equipped.
Rear Brake Caliper and Master Cylinder - VRSC Models
NOTE
For VRSC models: Instead of replacing the rear brake caliper banjo bolt, one of the banjo bolts can be used to replace the banjo bolt on the clutch master cylinder/reservoir. See subtopic VRSC Clutch Master Cylinder/Reservoir.
1.
Remove radiator right side cover to access master cylinder.
NOTE
Put a container under the master cylinder to catch brake fluid that may flow from brake line when removing banjo bolt.
2.
See Figure 3. Remove the banjo bolt (1) and two gaskets. Discard banjo bolt and gaskets.
3.
Lubricate new gaskets (2) with appropriate clean brake fluid.
4.
Install new gaskets on each side of brake line. Insert the banjo bolt through the gaskets and fitting. Tighten banjo bolt to 17–20 N·m (12.5–14.5 ft-lbs).
1Banjo bolt
2Gasket (2)
Figure 2. Rear Brake Caliper (brake line shown removed) - VRSC Shown
1Banjo bolt
2Gasket (2)
Figure 3. Rear Brake Master Cylinder/Reservoir
VRSC Clutch Master Cylinder/Reservoir
1.
See Figure 4. Loosen both screws (3) on the reservoir cover (4) to relieve pressure in master cylinder reservoir.
NOTE
Put a container under the banjo bolt. Brake fluid will begin draining from the reservoir as the banjo bolt is removed.
WARNING
Be sure no clutch fluid gets on tires, wheels or brakes when draining fluid. Traction can be adversely affected, which could result in loss of control and death or serious injury. (00295a)
2.
Slowly loosen banjo bolt (1) and allow brake fluid from reservoir to drain into cup.
3.
Remove banjo bolt (1) and two gaskets (2).
4.
Install new banjo bolt with new gaskets.
5.
Refer to the service manual and fill reservoir.
6.
Verify that the fluid level in the clutch fluid reservoir is at the FULL level with the motorcycle in an upright position.
NOTE
Clutch fluid volume increases with clutch wear. Do NOT overfill the clutch reservoir.
7.
Verify the pressure by squeezing the clutch hand lever.
8.
Tighten the fasteners:
a.
Banjo bolt (1): 17–20 N·m (12.5–14.5 ft-lbs)
b.
Reservoir cover screw: 0.7–0.9 N·m (6–8 in-lbs)
1Banjo bolt
2Gasket (2)
3Cover screw (2)
4Reservoir cover
Figure 4. Clutch Master Cylinder/Reservoir
Bleed the Brakes and Clutch
NOTICE
DOT 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239c)
WARNING
Contact with DOT 4 brake fluid can have serious health effects. Failure to wear proper skin and eye protection could result in death or serious injury.
  • If inhaled: Keep calm, remove to fresh air, seek medical attention.
  • If on skin: Remove contaminated clothing. Rinse skin immediately with plenty of water for 15-20 minutes. If irritation develops, seek medical attention.
  • If in eyes: Wash affected eyes for at least 15 minutes under running water with eye lids held open. If irritation develops, seek medical attention.
  • If swallowed: Rinse mouth and then drink plenty of water. Do not induce vomiting. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240d)
NOTE
Hydraulic brake fluid bladder-type pressure equipment can be used to fill brake master cylinder through the bleeder valve. Remove master cylinder/reservoir cover so that system cannot pressurize. Do not use pressure bleeding equipment when the hydraulic system is sealed with master cylinder reservoir cover and gasket in place.
  1. Bleed the brakes following the instructions in the service manual.
  2. For VRSC Models: Bleed the clutch if the banjo bolt on the clutch cylinder/reservoir has been replaced. Follow the instructions in the service manual.
Return the Motorcycle to Service
WARNING
Connect positive (+) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00068a)
  1. Connect negative (-) battery cable to battery following instructions in the service manual.
Test the Brakes
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
  1. Turn ignition switch ON.
  2. Pump brake hand lever to verify operation of the brake lamp.
  3. Test ride the motorcycle. If the brakes feel soft, bleed the brake system again.
SERVICE PARTS
Figure 5. Service Parts: Chrome Banjo Bolt Kit
Table 1. Service Parts: Chrome Banjo Bolt Kit
Item
Description (Quantity)
Part Number
1
Banjo bolt (3)
5468M
2
Banjo bolt/bleeder screw assembly (2)
41735-08
3
Gasket, brake line (10)
41751-06A