Brake Banjo Question

I'm replacing the brake lines and master cylinder on one of my project bikes. The banjo bolt is supposed to be a 12mm bolt, so I need a 12mm banjo. Should the ID of the banjo bolt hole measure out to 12mm ??

My dilemma is, I purchased a 12mm banjo, and the 12mm bolt, that came with the new master cylinder, does not go through the banjo bolt hole. I measured the banjo bolt hole and it is 11.25mm. No way the 12mm bolt is going through that hole.

The seller of the banjo is claiming they sent me the correct part, when it sure looks like I got a piece of junk. Are there 11mm banjo's and banjo bolts ?? Everything I've seen is either 10mm or 12mm.

I'm thinking this banjo that I purchased, didn't get completed in the manufacturing process. Which is why it measures 11.25mm, and not 12mm.

What do you guys think ??

Instead of faffing around with it,can you not just use your original bolts? Clean them up and put them in. At least you know that they are the right diameter and the right thread.

Not able to do that. I've purchased a new, throttle assembly / master cylinder assembly / brake lever assembly, and switch housing, and a new brake line for the bike.

skooterbum4real wrote: I'm replacing the brake lines and master cylinder on one of my project bikes. The banjo bolt is supposed to be a 12mm bolt, so I need a 12mm banjo. Should the ID of the banjo bolt hole measure out to 12mm ??

My dilemma is, I purchased a 12mm banjo, and the 12mm bolt, that came with the new master cylinder, does not go through the banjo bolt hole. I measured the banjo bolt hole and it is 11.25mm. No way the 12mm bolt is going through that hole.

The seller of the banjo is claiming they sent me the correct part, when it sure looks like I got a piece of junk. Are there 11mm banjo's and banjo bolts ?? Everything I've seen is either 10mm or 12mm.

I'm thinking this banjo that I purchased, didn't get completed in the manufacturing process. Which is why it measures 11.25mm, and not 12mm.

What do you guys think ??

Make sure the threads are the same pitch. You can have two of the same sized bolts, but with different thread pitches.

Made in CHINA?
Steve

Does the bolt fit the master cylinder properly? If so, then you certainly need a different banjo.

When I was wrenching on these bikes in the day, the bolts were standard metric. That's why I asked where it was made. You might be able to drill it to fit.
Steve

skooterbum4real wrote: I'm replacing the brake lines and master cylinder on one of my project bikes. The banjo bolt is supposed to be a 12mm bolt, so I need a 12mm banjo. Should the ID of the banjo bolt hole measure out to 12mm ??

The stock Kawasaki banjo bolts are 10 mm and the stock banjos have a 10 mm hole - so yes, the ID of the banjo hole should measure out to the same diameter as the banjo bolt, in your case 12 mm. The banjo bolts have a recess iwhere the holes are to allow the brake fluid to flow.

The seller of the banjo is claiming they sent me the correct part, when it sure looks like I got a piece of junk. Are there 11mm banjo's and banjo bolts ?? Everything I've seen is either 10mm or 12mm.

There may be 11 mm banjos and banjo bolts, but I have never seen them, either 10 or 12 as you say. Usually metric sizes jump in 1 mm increments below 6 mm, and 2 mm increments above - standard sizes go 3, 4, 5, 6, 8, 10, 12, 14 etc. - there are odd sizes (7, 9, 11 etc) out there but they are uncommon.

The 11.25 hole is a very odd size, does it come close to any standard inch size? As Steve said you should be able to drill the hole out to 12 mm or better yet have it reamed.

Why buy from places who cannot help you get the correct part?

You may save a couple of dollars and end up with massive headaches...

You need 10mm x 1.25mm pitch.

When you measure bolts, you measure the THREAD diameter, Most threads will be slightly undersized, so a 10mm bolt will measure 9.85mm - this gives enough clearance to thread the bolt into the hole.

I wouldnt go drilling anything out.A banjo bolt costs bog all. If you go to your local bike shop,he'll probably have a box full of odd nuts and bolts etc that you can sift through.
Dont like the idea of bodging it on brakes. Its better to spend the money and get quality bits.
Plus,
The problem with buying Chinese parts for your bike is that half an hour later you want to buy more!

Thanks everyone for your help !!

This banjo must be a reject that missed an operation in the manufacturing process.

The master cylinder assembly came with the banjo bolt, and yes it fits the hole in the master cylinder fine. the problem lies with this piece of poop banjo that I purchased. I was wanting your views to make sure I knew what I was talking about, to be able to send the banjo back to the seller, if in fact it was defective, which it must be.

The seller was expecting me to pay the return shipping, which after your help, I will not be doing.

Ebay? File not as described, get your money back and if he sends you a shipping label, send it to him.
Steve