01xxallen Posted November 22, 2006 Share Posted November 22, 2006 I'm about half way through installing heli bars. So far so good, but I've hit a snag on the clutch banjo bolt. I have to rotate the line out, but I can't budge the banjo bolt. The brake side was snug but do-able. I guess I'm asking: How strong are those? I'd hate to break it :icon_wall: Maybe a little heat from a heat gun? Tap it a few times? Curse? Quote Link to comment Share on other sites More sharing options...
Para045 Posted November 22, 2006 Share Posted November 22, 2006 I'm about half way through installing heli bars. So far so good, but I've hit a snag on the clutch banjo bolt. I have to rotate the line out, but I can't budge the banjo bolt. The brake side was snug but do-able. I guess I'm asking: How strong are those? I'd hate to break it :icon_wall: Maybe a little heat from a heat gun? Tap it a few times? Curse? Are you trying to undo the bolt while the MC is off, if so it will be a lot harder to undo, maybe try putting the MC back on the original clip on and the clip on loosely on the fork just to get some leverage :icon_think: Just enough to "break the bond" so to speak, also I assume you have taken the lug off the screen side of the MC so that the banjo will rotate once it is loose Quote Link to comment Share on other sites More sharing options...
01xxallen Posted November 22, 2006 Author Share Posted November 22, 2006 I'm about half way through installing heli bars. So far so good, but I've hit a snag on the clutch banjo bolt. I have to rotate the line out, but I can't budge the banjo bolt. The brake side was snug but do-able. I guess I'm asking: How strong are those? I'd hate to break it :icon_wall: Maybe a little heat from a heat gun? Tap it a few times? Curse? Are you trying to undo the bolt while the MC is off, if so it will be a lot harder to undo, maybe try putting the MC back on the original clip on and the clip on loosely on the fork just to get some leverage :icon_think: Just enough to "break the bond" so to speak, also I assume you have taken the lug off the screen side of the MC so that the banjo will rotate once it is loose Yes, I dremmeled off the lug. Put the clutch back on the origional bar. I pulled hard enough to rotate the clutch assembly on the bar, but no joy on the banjo bolt. Quote Link to comment Share on other sites More sharing options...
Toynut Posted November 22, 2006 Share Posted November 22, 2006 I would be really nervous about applying heat to that area. The m/cyl paint/rubber seals/brake fluid do not take very kindly to heat. Get a well fitting wrench on the bolt and try tapping it firmly but not abusively with a heavy soft blow hammer. You will be replicating the actions of an impact socket (don't even think of an air gun). That may be just enough to "break" the bolt's hold. A touch of penetrating oil MIGHT help a bit. It's possible that the washers have also stuck between the bolt and m/cyl housing. Make sure that the clip on and the m/cyl housing are both tight. Don't forgrt to put a towel under it, in case you lose some fluid. If the fluid looks dark or you let some air into the system, be prepaired to bleed it, too! Quote Link to comment Share on other sites More sharing options...
dosequis driver Posted November 22, 2006 Share Posted November 22, 2006 It's been a long time, but I seem to recall that I ran into a stiff banjo bolt as well. If memory serves, I applied counter-clockwise pressure on the banjo fitting while I cranked on the bolt (also counter-clockwise) and it came loose without too much effort. Quote Link to comment Share on other sites More sharing options...
01xxallen Posted November 22, 2006 Author Share Posted November 22, 2006 Thanks to all, I'll give it another try. Quote Link to comment Share on other sites More sharing options...
01xxallen Posted November 23, 2006 Author Share Posted November 23, 2006 Thanks for all who responded. I did everything. A little heat, so I could still touch it, a few taps, a little spray. I ended up putting a large screwdriver between the M/C and the old bars so it wouldn't turn, and turned the wrench. It broke free with a snap, but nothing broke. I even had a bowl standing by to catch the fluid if it broke. New bars went on like butter. Quote Link to comment Share on other sites More sharing options...
Toynut Posted November 23, 2006 Share Posted November 23, 2006 Bravo! :icon_clap: Is your brake fluid due for a change, yet? Quote Link to comment Share on other sites More sharing options...
googus Posted July 1, 2008 Share Posted July 1, 2008 I thought that you did not need to move anything when installing heli bars? Quote Link to comment Share on other sites More sharing options...
Para045 Posted July 2, 2008 Share Posted July 2, 2008 I thought that you did not need to move anything when installing Heli bars? You shouldn't need to on Heli's, only with the VFR bars should the banjo need to be rotated to clear the clip on Quote Link to comment Share on other sites More sharing options...
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