Which Brake Lines are the Right Lines?

Hi all,

I have needed new brake lines ever since I bought my 550 Seca, but I have never exactly known what lengths to get or what fittings I need. And yes, they are the original '81 brake lines

Looking at the bike, I think they're banjo bolts, which are a universal fit, right? Well, they're near impossible to find in the right length for a reasonable cost and satisfactory marketing.

And then there's the problem of which lengths to choose. To the best of my knowledge, Yamaha put a splitter or sorts in the middle for some reason, and that divides the brake line into two pieces- upper and lower. The best I could to to measure them, without removing them and rendering the bike unridable, was with a tape measure and I got roughly, roughly 18 inches for the upper line and 20 inches for the lower line.

By the way, my mom's 550 Maxim ('81) has the same exact issues as mine:
Gushy lever and weak brakes
Hard lever and sticking brakes
Release pressure through bleeder valve
Top off master cylinder
Repeat
And, occasionally clean out the return hole in the master cylinder

What I think is happening is that gunk or bits of rubber are coming from the ancient lines back up into the master cylinder, clogging the return hole and causing this terrible cycle. And the lines are so wimpy they stretch under load, causing the squishy lever.

So basically my questions are as follows:

1. Should I look for banjo bolts harder or make do with adapters?
2. Is the banjo bolt even the right connection for my bike?
3. What are the actual lengths of the lines?
4. Can't I just use one longer line to connect the master cylinder and the caliper directly?

 

Yes, you should.

Yes, it is.

Don't know.

Yes, you can. That's what I have. Got it that way from previous owner.

You can get the exact replacement lines from Chacal. Or, you can get a custom line made, like I have done on my other bikes. Find a local business that makes hydraulic lines for industrial machinery. They often make brake lines, but don't really advertise it. Where I live, we have a franchise of a company called Pirtek. They have super high quality brake hoses and they stock 10mm banjo fittings that they will bend to your specifications.

 

If I am understanding your post correctly, you do not want to remove the brake lines to get an accurate measurement because the bike will then be out of commission.

Is that the same as saying; "I know my brake lines are as old as dirt and can fail at any moment, but they have worked 'ok' so far, they won't fail on this trip".

Spend some money Kyle, (I would get them from XJ4Ever), otherwise you may find out that there are other things that are ALOT more expensive.

 

if your brake lines need to be replaced you also need to rebuild your calipers and MC you should do this all at the same time and tell your mother to do this too.
use a string to measure then measure the string.
or just email len ask him for a price www.xj4ever.com you will get a line with crimped connections safest way to go.

don't forget the copper crush washers
from www.xj4ever.com
1981-83 XJ550 Seca North American models:

NOTE: for US & Canadian models with a single front disc brake.

HCP2825RU Reproduction DOT-approved rubber BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint on the lower steering bracket.
$ 37.95

HCP2826RU Reproduction DOT-approved rubber BRAKE LINE ASSEMBLY, from the distribution joint on the lower steering bracket to the right front brake caliper. Includes the rubber sleeve grommet for the hose routing bracket.
$ 44.95

you have read this about the rear brakes
SAFETY ALERT Drum rear brake bike owners please take a look