Replacing the braided stainless brake line the previous owner installed on the sidecar with the factory rigid line. Does anybody have a '92 FLHTC/TLE rig that you can take a few photos of the brake line routing for me? I'm particularily interested in how the rigid line routes from along the lower rear connection and over (or under) the inboard end of the axle carrier the over to the slave cylinder. Yes, I know the braided stainless looks neater, but if I decide to add a brake proportioning valve, it will be easier (and cheaper) to have the rigid line cut and re-flared to fit the proportioning valve. Also, using the rigid line eliminates the adapters from 3/16 NPT to #3 AN fittings and thus eliminating the potential for leaks. The rigid line also blends in better and isn't so obvious.
Thanks,
Duane
PS. Oh yeah, by my reckoning, '92 to '95 should be the same as it looks like significant changes occurred in '96.
dunesie - 8/3/2010 8:16 PM
Replacing the braided stainless brake line the previous owner installed on the sidecar with the factory rigid line. Does anybody have a '92 FLHTC/TLE rig that you can take a few photos of the brake line routing for me? I'm particularily interested in how the rigid line routes from along the lower rear connection and over (or under) the inboard end of the axle carrier the over to the slave cylinder. Yes, I know the braided stainless looks neater, but if I decide to add a brake proportioning valve, it will be easier (and cheaper) to have the rigid line cut and re-flared to fit the proportioning valve. Also, using the rigid line eliminates the adapters from 3/16 NPT to #3 AN fittings and thus eliminating the potential for leaks. The rigid line also blends in better and isn't so obvious.
Thanks,
Duane
PS. Oh yeah, by my reckoning, '92 to '95 should be the same as it looks like significant changes occurred in '96.
Hello, Sorry, I don't have pictures since my sidecar is 2007. The change to the brake line was in 1998. when they changed to the disc brake assembly. Besides a slightly different routing on the brake end, the fitting was changed from a 3/16" male brake tube fitting which went into the cylinder in the brake drum to a banjo fitting for a hollow bolt which threads into the 1998 on disc brake caliper.
The other end, where there is a rubber brake hose, is virtually the same. On motorcycles up to the Twin Cam, IIRC, the master cylinder was rear mounted under the transmission outer right side case. The brake hose screwed directly into the master cylinder at that point.
On the later bikes, the master cylinder went up front near the brake pedal. The brake hose still threads into the system under the transmission right side cover but it goes into a brass tee that is part of the sidecar connection kit.
It's a shame that the brake line that you need, 827095-85, is NLA (No longer avaiilable) since they weren't very expensive (less than $20) and it would have fit your 1992 TLE with no changes.
Nonetheless, the routing was nothing special - just out of the wheel cylinder, down and over to the rear frame cross tube under the rear of the tub to the left side of the frame, then turning forward about a foot to jog left where the rubber brake hose (about a 12-14" hose, IIRC) connects to the master cylinder.
Hopefully someone has a pre-1998 rig and can give you some photos. If I had the proper rig, I'd be happy to do some photos.
Good luck.
