Brake hoses.

toglhot

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Brake hoses came this afternoon, 1 x 500mm and 1 x 400mm. These were hard to track down as they were the only ones rated JB1401. I also bought some stainless banjo bolts, two M10 x 1.25 and two M10 x 1. these do away with the need for the two steel pipes.

The 500mm one is a good fit on the bottom, but the hose does have to go under the guard tunnel, which works out well because I was going to make a fork brace/guard mount anyway. I found the banjo just fits on the calliper if two washers are place under the banjo. With only one, the banjo hits against the calliper.

Later on I'll probably machine up a longer banjo bolt and a spacer. The 400mm hose is a bit long for the top hose, but I found if the hose exits the divider on the left and is brought behind the headlight, it's a good fit.

The banjos at either ends of the hoses are on the same plane, the top one is OK if the hose is angled on the divider correctly, but the lower banjo is off a few degrees.

Best part is the price: $Aus16 each for the hoses and $Aus8 for the four bolts.
 

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bosco659

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I just went through a similar exercise with my upper brake hose. Fortunately for me, the hose I replaced had removable banjo’s so they could be clocked to the ideal angle without issue. The po had double stacked crush washers to gain clearance but I managed to make a 45° fitting work that eliminated the need for the extra washer. I’d still like to shorten the two hoses going from under the forks to the calipers but that can wait.

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DogBunny

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bosco659

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I addressed making your own brake hoses a while back in the following thread, post # 82:
https://www.xs650.com/threads/1973-super-rustbucket-resurrection.58711/page-5#post-699492
You will see how the hose I made does go through the fender tunnel.
Also, when you make your own hose, you can place the banjo at whatever angle works best.
Yes, making your own hoses would be great but I didn’t want to get into the expense of buying the bulk hose for only the one line. I have another project on the horizon that may justify (in my mind) the investment.
 

bosco659

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I addressed making your own brake hoses a while back in the following thread, post # 82:
https://www.xs650.com/threads/1973-super-rustbucket-resurrection.58711/page-5#post-699492
You will see how the hose I made does go through the fender tunnel.
Also, when you make your own hose, you can place the banjo at whatever angle works best.
Dog, where did you get the sealing washers? I bought some but like the look of yours better. Did they hold up well over the years?
 

DogBunny

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Dog, where did you get the sealing washers? I bought some but like the look of yours better. Did they hold up well over the years?
he copper ones, or the metal and rubber ones?
The copper ones came with the HEL fitting I showed in my post. They are the same as stock XS650. You can anneal and re-use old ones. Annealing is quick and easy.
The metal and rubber ones come when you buy new master cylinders. They work fine, but I don't think they are reusable, which is why I usually prefer the copper ones.
 

bosco659

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he copper ones, or the metal and rubber ones?
The copper ones came with the HEL fitting I showed in my post. They are the same as stock XS650. You can anneal and re-use old ones. Annealing is quick and easy.
The metal and rubber ones come when you buy new master cylinders. They work fine, but I don't think they are reusable, which is why I usually prefer the copper ones.
I was referring to the rubber ones. I find they come in handy with difficult to seal applications.
 

toglhot

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You can buy copper washer kits, they are handy when building engines, I bought this 150 piece kit a couple of months ago for under $10.
Making your own hose is fine if you have more than a couple to do. However, the outlay for hose, fittings and tools will cost you far more than a couple of new hoses from an XS650 parts outlet. I would also check on your countries hose requirements. Ours are JB1401. It can be difficult to find rated hoses.
 

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