Rear brake master cylinder banjo bolt stripped WTF? - Victory Forums - Victory Motorcycle Forum
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post #1 of 13 (permalink) Old 09-02-2012, 01:05 AM Thread Starter
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Default Rear brake master cylinder banjo bolt stripped WTF?

i just added 4" extensions to my Kingpin Tour. When re-installing the banjo bolt on the rear master cylinder the threads stripped out long before my torque wrench hit the 20 lb-ft torque setting. The threads came out attached to the banjo bolt in a single piece -as if they were some cheap pot-metal crap. I've never seen anything like it.

As a long-time Harley rider I'm totally dumbfounded. I have a high-quality click torque wrench and followed the factory service manual for the procedure.

I'm now out $120 for a new master cylinder and am terrified that the new unit will again strip out before reaching the torque specified in the service manual.

Has anyone else suffered a similar fate? What the hell?
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post #2 of 13 (permalink) Old 09-02-2012, 09:59 AM
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It is cheap pot metal made in china... torque wrenches sometimes are not the answer to proper tightening. I have been riding and servicing motorcycles for 50+ years and have never used a torque wrench... go figure. And have never had a problem with not tightening whatever properly.

Screw a nut on a bolt that is run thru something to hold it when you use your torque wrench... then test it with another torque wrench. If you only have the one wrench find a friendly full service mechanic who let you compare your wrench with his.

OR... throw away the torque wrench and learn how to gauge tightening without it.

Handy

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post #3 of 13 (permalink) Old 09-02-2012, 12:49 PM
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Hey you 2 add to your profile where you live.
I might find a rear caliper for you

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Mpls, MN.

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post #4 of 13 (permalink) Old 09-02-2012, 12:59 PM
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Say why not head over to auto store and see about a heli coil kit

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post #5 of 13 (permalink) Old 09-02-2012, 02:22 PM
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Quote:
Originally Posted by avalonpb View Post
i just added 4" extensions to my Kingpin Tour. When re-installing the banjo bolt on the rear master cylinder the threads stripped out long before my torque wrench hit the 20 lb-ft torque setting. The threads came out attached to the banjo bolt in a single piece -as if they were some cheap pot-metal crap. I've never seen anything like it.
My service manual says to torque it to 96 in/lbs. that would be 8 ft/lbs.
rear master.png

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post #6 of 13 (permalink) Old 09-02-2012, 10:48 PM Thread Starter
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My service manual says to torque it to 96 in/lbs. that would be 8 ft/lbs.
Attachment 7853

Thank you!!!! That confirms there is an error in my 2007 service manual. I was thiking there must be be given the way the threads pulled completely out. I triple checked and the 2007 service manual clearly states the torque on the banjo bolt as 20-22 lb- ft.

I figured it was either a mis print or some torque-by-feel mechanic prior to me wrenched it down right good and weakened e threads before I bought the bike.

Thanks again.

Last edited by avalonpb; 09-02-2012 at 11:12 PM.
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post #7 of 13 (permalink) Old 09-02-2012, 11:10 PM Thread Starter
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In the hopes of helping someone else avoid this BS. Clearly the 2007 Victory Kingpin/Vegas/Jackpot service manual is wrong. Torquing the master-cylinder banjo bolt to the service manual specs destroyed my master cylinder (at a cost of $120).

Below are the specs from the 2007 Victory Factory Service Manual. Note, torquing the bolt to this spec will likely destroy the master cylinder. The 2008 manual corrects this spec. to 96 in-lb (8 ft-lb)




Last edited by avalonpb; 09-03-2012 at 11:19 AM.
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post #8 of 13 (permalink) Old 09-02-2012, 11:29 PM Thread Starter
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Say why not head over to auto store and see about a heli coil kit
Thought about that. $50 for the kit, plus the time to install, risk it won't seal and/or metal filings contaminate the brake system...

I figured my life was worth doing it right.
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post #9 of 13 (permalink) Old 09-03-2012, 07:42 AM
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Quote:
Originally Posted by avalonpb View Post
I figured it was either a mis print or some torque-by-feel mechanic prior to me wrenched it down right good and weakened e threads before I bought the bike.

Thanks again.
Torque by feel is only as good as the "mechanic" doing it... don't slam others for your shortcomings. My feel technique holds true for me and I have never sheared off a brake banjo bolt because I used an improper torque value... a good mechanic would know up front that 20-22 ftlbs was way too much torque... wrench or not!!!

Handy

2013 Indian Vintage Chief FE... #7 of 25

2011 Victory Vision Tour Premium...
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post #10 of 13 (permalink) Old 09-03-2012, 09:41 AM
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Just to let you know, the caliper torque is 18ft/lbs which is also different from the 07 manual. Should'nt be enought difference to matter on it.
caliper.png

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