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CHROME BANJO BOLT KIT
J037982006-09-11
GENERAL
Kit Number
41842-06
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
This kit does not fit models equipped with Banjo Bolt Cover (32715-98).
Additional Parts Required
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)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
Kit Contents
See Figure 3 and Table 1.
INSTALLATION
Prepare the Motorcycle for Service
1. Remove the seat following the instructions in the Owner's Manual.
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
2. Disconnect the negative (-) battery cable following the instructions in the Service Manual.
Front Brake Caliper and Master Cylinder
NOTE
When performing the following step, place a container under caliper to catch brake fluid that may flow from brake line when removing banjo bolt.
CAUTION
Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b)
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. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
NOTICE
Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a)
1. Remove the banjo bolt and steel/rubber gaskets to detach front brake line from caliper. Discard gaskets and banjo bolt.
NOTE
Check your Owner's Manual for information on the correct brake fluid for your model motorcycle.
1Master cylinder banjo bolt
2Master cylinder banjo bolt gaskets
3Brake caliper banjo bolt
4Brake caliper banjo bolt gaskets
Figure 1. Install Banjo Bolts
NOTICE
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and caliper bore are clean and undamaged before assembly. (00321a)
2. Lubricate new steel/rubber gaskets with appropriate hydraulic brake fluid.
3. Install new steel/rubber gaskets (4), brake line and banjo bolt (3) onto the caliper in the order shown in Figure 1. Tighten banjo bolt to 23–29.8 N·m (17–22 ft-lbs).
4. Remove the banjo bolt (1) and steel/rubber gaskets (2) to detach front brake line from master cylinder. Discard gaskets and banjo bolt.
NOTE
Check your Owner's Manual for information on the correct brake fluid for your model motorcycle.
5. Lubricate new steel/rubber gaskets with appropriate hydraulic brake fluid.
6. See Figure 1. Position a new steel/rubber gasket (2) on each side of brake line banjo fitting. Insert banjo bolt (1) through washers and fitting. Thread bolt into master cylinder housing. Tighten to 23–29.8 N·m (17–22 ft-lbs).
7. See the Bleed the Brakes section of this Instruction Sheet and bleed the brakes.
1Chrome Banjo Bolt
2Steel/rubber gaskets
3Rear brake line
Figure 2. Rear Brake Caliper Installation
Rear Brake Caliper
NOTE
When performing the following step, place a container under caliper to catch brake fluid that may flow from brake line when removing banjo bolt.
1. Remove the banjo bolt and steel/rubber gaskets to detach rear brake line from caliper. Discard gaskets and banjo bolt.
NOTE
Check your Owner's Manual for information on the correct brake fluid for your model motorcycle.
2. Lubricate new steel/rubber gaskets with appropriate hydraulic brake fluid.
3. Install new steel/rubber gaskets (2), brake line and banjo bolt (1) onto the caliper in the order shown in Figure 2. Tighten banjo bolt to 23–29.8 N·m (17–22 ft-lbs).
4. Remove the banjo bolt and steel/rubber gaskets to detach rear brake line from rear master cylinder. Discard gaskets and banjo bolt.
NOTE
Check your Owner's Manual for information on the correct brake fluid for your model motorcycle.
5. Lubricate new steel/rubber gaskets with appropriate hydraulic brake fluid.
6. Position a new steel/rubber gasket on each side of brake line banjo fitting. Insert banjo bolt through washers and fitting. Thread bolt into rear master cylinder housing. Tighten to 23–29.8 N·m (17–22 ft-lbs).
7. See the Bleed the Brakes section of this Instruction Sheet and bleed the brakes.
Bleed the Brakes
CAUTION
Direct contact of DOT 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of DOT 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144b)
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. Contact Poison Control. Immediate medical attention required.
  • See Safety Data Sheet (SDS) for more details available at sds.harley-davidson.com
(00240e)
NOTE
This kit can be used with brake systems that use D.O.T. 4 or D.O.T. 5 Hydraulic Brake Fluid. Be sure to review your Owner's Manual or see a Harley-Davidson Dealer to determine the correct brake fluid for your motorcycle.
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. See an appropriate Service Manual and bleed the brakes.
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. Install maxi-fuse and right-side cover.
WARNING
After installing seat, pull upward on seat to be sure it is locked in position. While riding, a loose seat can shift causing loss of control, which could result in death or serious injury. (00070b)
2. Follow the instructions in the Service Manual to install the seat.
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 spongy, bleed the brake system again.
SERVICE PARTS
Figure 3. Service Parts: Chrome Banjo Bolt Kit
Table 1. Service Parts: Chrome Banjo Bolt Kit
Item
Description (Quantity)
Part Number
1
Banjo bolt (3)
5466
2
Steel/rubber gasket (6)
41731-01
3
Banjo bolt
5467
4
Steel/rubber gasket (2)
41733-88