Single Stainless Brake Line Upgrade for 1976XS

wideload · Aug 18, 2019

I've been looking through posts about this upgrade & I would like to replace upper and lower brake lines with a single stainless steel braided line.
I haven't come across a discussion regarding the hydraulically activated front brake switch, which is located in the brake line joint (where the upper and lower hoses are connected). If I use a single brake line, what is the work around for a brake switch?

Ratranger · Aug 18, 2019

Get a banjo bolt brake switch. I'm using 2 of these https://www.amazon.com/Motorcycle-H...ch&qid=1566168043&s=gateway&sr=8-4&th=1&psc=1 . no issues, brake lights come on with very little pull on the lever.

wideload · Aug 18, 2019

Ratranger said:
Get a banjo bolt brake switch. I'm using 2 of these https://www.amazon.com/Motorcycle-Hydraulic-Pressure-Universal-Scooter/dp/B07JGLZMHD/ref=mp_s_a_1_4?keywords=m10+banjo+bolt+switch&qid=1566168043&s=gateway&sr=8-4&th=1&psc=1 . no issues, brake lights come on with very little pull on the lever.

Thanks for the suggestion. I suppose the best location for this banjo bolt would be at the MC. Looks like I would have to extend the wiring, but you cant have everything.

Ratranger · Aug 18, 2019

Yep, put it at the MC, I have one front and rear on mine.

wideload · Aug 18, 2019

solo2racr said:
The other option would be to change masters as well to one with the brake light switch built onto it. The up side is that it would look a bit cleaner.

It would look cleaner, wouldn't it. I'll need to look at the routing more closely, now that I am aware of the banjo bolt option.

Mailman · Aug 18, 2019

I installed a single braided steel line and a new master cylinder as well, on my 77D, you can see it here.
Post #838
http://www.xs650.com/threads/my-60th-birthday-present.47639/page-42#post-515367

Mailman · Aug 18, 2019

I installed a banjo , in-line brake switch on my XS2, works perfectly, but I can’t say I’m crazy about the look of it.

GLJ · Aug 18, 2019

Mailman said:
I installed a banjo , in-line brake switch on my XS2, works perfectly, but I can’t say I’m crazy about the look of it.
View attachment 147673

It is possible to put your original brake lite switch on that master cylinder. You just need a drill press or a very steady hand. :geek:

Mailman · Aug 18, 2019

Bunch of us here are running this line from Banggood.

Banggood brake line is the one I used on my 77D , 90cm long. Should be something like $8.99 and free shipping.

https://m.banggood.com/50cm-200cm-M...utm_medium=aff&sscid=81k3_gxnh2#popupStatePOA

willis · Aug 18, 2019

Another option would be to run a 2piece stainless line and keep your switch at the factory junction block.

wideload · Aug 19, 2019

Thanks for the information & pictures...
It would be nice to eliminate some of the joints using a single line, but I think I will go with braided upper and lower hoses for the sake of appearance & ability to use the stock brake switch

arcticXS · Aug 19, 2019

solo2racr said:
The other option would be to change masters as well to one with the brake light switch built onto it. The up side is that it would look a bit cleaner.

And one could choose a smaller master cylinder bore at the same time, for more feel and less braking effort. OEM Yamaha master cylinders from the 70s and early 80s were generally way too big. I am using a 13 mm "coffin reservoir" Brembo on both my RD and my XS, stock caliper on the RD and 4 pot Brembo on the XS. An added benefit is significantly lighter master cylinders, 200 g or more.

Norton7d · Aug 19, 2019

Mailman said:
Bunch of us here are running this line from Banggood.

Banggood brake line is the one I used on my 77D , 90cm long. Should be something like $8.99 and free shipping.

https://m.banggood.com/50cm-200cm-M...utm_medium=aff&sscid=81k3_gxnh2#popupStatePOA

Mailman, does this mean you also removed the steel hardline that from the factory attached to the caliper, thus allowing both ends of your steel braided line to have banjos?

wideload · Aug 19, 2019

Does anyone know how the length of Banggood brake lines are measured? Does that company use the total length, the center to center distance, or just the line between the banjo fittings?

Norton7d · Aug 19, 2019

wideload said:
Does anyone know how the length of Banggood brake lines are measured? Does that company use the total length, the center to center distance, or just the line between the banjo fittings?

Also, do the Banggood lines come with the wire-wound protector on the upper portion?
And are the banjo(s) angle of bend predetermined? or is that up to us to determine?

Mailman · Aug 19, 2019

Norton7d said:
Mailman, does this mean you also removed the steel hardline that from the factory attached to the caliper, thus allowing both ends of your steel braided line to have banjos?

My 77D did not have a steel line at the caliper. My XS2 did. This image was the original brake line set up on my 77.
So to answer your question, yes both ends of the brake line was a banjo fitting.

Mailman · Aug 19, 2019

Norton7d said:
Also, do the Banggood lines come with the wire-wound protector on the upper portion?
And are the banjo(s) angle of bend predetermined? or is that up to us to determine?

I had to go look, haha! :laugh2:

Answer is....one straight and one bent ( don’t know how many degrees ) I put the straight one at the top,

And the bent one at the bottom. ( I see my next job....paint that nasty caliper! )

Mailman · Aug 19, 2019

Oh, and no the hose does not have the coil spring protector. It is a braided steel line covered by a clear protective plastic, that doesn’t show well in photographs.

And I’m unsure how Banggood takes their measurements.

Norton7d · Aug 19, 2019

Mailman said:
Oh, and no the hose does not have the coil spring protector. It is a braided steel line covered by a clear protective plastic, that doesn’t show well in photographs.

And I’m unsure how Banggood takes their measurements.

The picture of your upper banjo looks shiney (polished" but the banjos on Banggood site appear to the be deep green color banjos I see on other bikes, did you remove the green coloring?

Mailman · Aug 19, 2019

Nope, they came chromed. I have read accounts from other guys that have ordered Banggood lines and been surprised when they showed up with bright red boots ( the sleeve that covers the transition from brake line to banjo fitting ) .
The line quality seems very good from Banggood, but it is a Chinese retailer and sometimes you can get a surprise. There are certainly domestic companies that specialize in brake products, that quality is top notch, and you will get exactly what you want.....for a price.

Single Stainless Brake Line Upgrade for 1976XS

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