Definitely 8mm - put a vernier on the one on there at the moment, which I reckon is the original fitment.
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75 model front brake master cylinder option.
- Thread starter AlanW
- Start date
Definitely 8mm - put a vernier on the one on there at the moment, which I reckon is the original fitment.
SteveP
XS650 Addict
SteveP
XS650 Addict
I think it was more like 30, possibly 35 degree. Definitely a 10mm banjo bolt. Have you got a spare Banjo bolt, to try?
SteveP
XS650 Addict
If you try a banjo bolt in the caliper don't force it. It may be the wrong pitch. You don't want to damage the thread in the caliper
Be specific when looking at the steel lines. The '75 is a 2 piece front brake line that has two steel lines. One on the upper line that plumbed into the brake light switch mount and the other on top of the caliper. The attached picture from Heiden appears to be the upper line going into the brake light switch mount. The lower steel line has very specific bends to route between the fork leg and the fender.
SteveP
XS650 Addict
In the tech section of this site there's a link to https://www.biker.net/
It's a great resource. Go to manuals for our bikes and you will find parts lists.
It's a great resource. Go to manuals for our bikes and you will find parts lists.
That’s great - thank you. I’m going to take a step back and re- assess what I’m going to do here.
So I ordered a single brake line from HEL down in Exeter. The MC fitting is a 20 degree Banjo with a M10 x 1 bolt for the Brembo. The fitting at the caliper - which is the early 2 piston in front of the fork variety - is a m10 x1 fitting which bolts straight in, replacing the old metal pipe (I now know how to properly read a Vernier !). Connected up the new Brembo micro switch to the wiring loom and the brake lights work! So far so good. Fresh Dot4 fluid in and started bleeding. The 11mm MC lever is still coming back to the bars so I’ve zip tied the lever overnight. Pads are hard on the disc. As per 5twins advice, I may be looking at 13 mm MC if I can’t sort this - potentially expensive mistake!! 
SteveP
XS650 Addict
It's a tricky process, bleeding these brakes. You may be OK with the m/c that you have. I can't exactly remember how I did mine.
I do remember getting loads of info by searching this site.
I do remember getting loads of info by searching this site.
Thanks Steve - and I owe you an apology over the caliper fitting size!! I was so chuffed I got the micro switch working - I’ll sleep on it and see what tomorrow brings!
You may be able to sell the 11 mm MC to someone with a 77 or newer XS with a single disc. The later calipers have a smaller, single piston, so the 11 mm would be an almost perfect fit for those.So I ordered a single brake line from HEL down in Exeter. The MC fitting is a 20 degree Banjo with a M10 x 1 bolt for the Brembo. The fitting at the caliper - which is the early 2 piston in front of the fork variety - is a m10 x1 fitting which bolts straight in, replacing the old metal pipe (I now know how to properly read a Vernier !). Connected up the new Brembo micro switch to the wiring loom and the brake lights work! So far so good. Fresh Dot4 fluid in and started bleeding. The 11mm MC lever is still coming back to the bars so I’ve zip tied the lever overnight. Pads are hard on the disc. As per 5twins advice, I may be looking at 13 mm MC if I can’t sort this - potentially expensive mistake!!
SteveP
XS650 Addict
Tbh it's not that bad. Get the m/c on Ebay. The rest should be fine.
Just find another slightly larger master cylinder.
The weather is horrible anyway. And you've learned quite a bit about hydraulic systems.
Just find another slightly larger master cylinder.
The weather is horrible anyway. And you've learned quite a bit about hydraulic systems.
