H there, Ive been looking around this site for awhile and have learned alot been looking for a sidecar for awhile also, finally found one, on this site as a matter of fact. So in trying to hook it up I have run into a problem hope someone here can help me out. ok I have a 2001 HD roadking and I bought a 2003 HD TLE now this sidecar came with all kinds of extra parts.I have all the mounts, but my problem is the brake hookup. I think the guy who had the sidecar before had it on a 2003 HD then ha bought a 2007 HD and hooked it to it. The brake line comming from the sidecar has a banjo style fitting on the end of it and I also have a double banjo bolt, trouble is it wont fit in the rear caliper on my 2001. I think its because he had it hooked to a 2007 HD and changed the brake line on the sidecar? do you think? I guess my question is can I find a double banjo bolt to fit my bike and if so would it still work with the fitting from the sidecar? the fitting from the sidecar is just a little bigger than the one on my bike, in other words the double bolt I have fits through the sidecar fitting but not the fitting on my bike Did Harly switch to Brembo brakes by then, is that the difference? Any suggestions will be appreciated. Ed
Sorry that I can't give you any information about your Harly. I'm sure one or more of the Harly guys will give you some info that will help, welcome to the site and the sidecar lifestyle. Good luck with your setup, and hope it works out great for you. Lloyd
Well, thanks anyway Lloyd, I'm sure someone on here will have some good ideas, I'm looking forward to getting this thing on the road!
If the double orifice bolt threads in and fits both fittings, but one diameter is bigger then the other, You can have somebody turn out of soft copper recessed seal washers that will align and center the bigger fitting.
Just a thought.
Sven
Sven, thanks for the thought, but the double banjo bolt that came with the sidecar is I believe a 12mm bolt it wont go in the caliper on my bike. The fittings on the bike I think are 10mm, so I think it will be just as easy to change the sidecar back to original or just get some universal brake lines the correct length with 10mm ends on them. and run them from the sidecar to the bike! plus get a 10mm double banjo bolt. guess I should have thought it out a little better, I think that will work, thanks anyway Sven. ed
I have a 93 Tour Glide with a 96 sidecar. I just put a double banjo bolt on my rear caliper to attach the sidecar brake line. You may have 3/8-24 threads on your rear caliper. I don't know what year they switched to 10 mm. My bike has 3/8-24 threads in the caliper. I found a double banjo bolt that worked at a Pirtek store that makes all kinds of hydraulic lines. You have to be careful with the length and diameter of the shoulders on the banjo bolt. The first one I bought worked ok with the 10 mm banjo fitting on my sidecar line but the 3/8 banjo from the bike would not fit over the shoulders.
you may be right, I went and checked and a 3/8 12pt. socket fit just right, but either way the double banjo bolt that came with the sidecar has a 1/2 in. hex head on it and the inner diameter of the end of the sidecar brake line looks like 1/2 in. also so it wont fit in the caliper on the bike. looks like I'll change the line on the sidecar. Thanks for your help. ed
There's some other stuff you may have to do with the brakes. On some newer model years than mine they put on a different brake pedal and master cylinder, but I don't know if you need that or not. Get the sidecar manual for your year bike and sidecar if you don't have them already. Good luck, Dave
Right, I think it was 2002 and newer you had to change the brake pedal, my 2001 is fine. plus the sidecar came with the remote resevior and I do have the manuals for both thanks again, ed
Yes 2002 and newer is when you had to change the brake pedal I did this on mine since it was a O2 but thinking about trying to make the stock one work as the stock one sure gives you more room on the floorboard. I have a O2 Ultra with a 06 HD sidecar and my line from the side car goes goes to a new fitting I installed where the brake light switch goes. I have it all hooked up just like factory manual says. Seems like if you hook it to the rear caliper on the bike would not be the best idea.
If you look on your frame in the front on the down tubes there is a bracket this is for the new reservoir for the brake. The stock master cylinder does not hold enough fluid for the sidecar brake. You need to take off you’re the reservoir and put a fitting made to hook the new reservoir to. On many older bikes the reservoirs where bigger. I have a HD sidecar manual for 1999 to 2004 and I did mine just like it said. I have not had a problem.
You all so have to put a fitting on your oil pressure switch to have it point down.
Good luck
46U, why do you think it would not be good to use a double banjo bolt on the rear caliper? Thanks, Dave
I am sure it has a rubber line going to it to help with the movement of the swing arm but I prefer to have mine hooked up to the brake light fitting like my HD manual says as it has no or very little movement. Yes I understand the stock line going to the caliber moves but it all so seems it would activate the rear brake before the sidecar brake. Just my 2 cents. Does any of the HD manuals show it hooked up the way you have it? Only official HD sidecar manuals I have covers 1999 to 2009 and all of them show hooking up to the brake light tee.
On my FLHX/Liberty rig i have the double banjo fitting connected to the rear brake master cylinder. Each brake then has it's separate line.
Lonnie
Hack'n - 1/9/2013 6:56 PM
On my FLHX/Liberty rig i have the double banjo fitting connected to the rear brake master cylinder. Each brake then has it's separate line.
Lonnie
In my opinion going to the master cylinder with both would be better then going to the caliper.
I went to the caliper because my bike does not have the stock tee fitting. The rear brake line had been modified from stock at some point in the bike's history. (Its a 93 that I bought in 2012.) I don't have it working yet, still need to bleed the system better, but maybe I will have to change my original plan.
