Inspection
1. Brake hose and pipe condition should be checked regularly (see Chapter 1).
2. Twist and flex the rubber hoses while looking for cracks, bulges and seeping fluid (see illustration). Check extra carefully around the areas where the hoses connect with the banjo fittings, as these are common areas for hose failure.
9.2. Flex the brake hoses and check for cracks, bulges and leaking fluid
3. Inspect the metal brake pipes and the banjo union fittings connected to the brake hoses. If the fittings are rusted, scratched or cracked, replace them with new ones.
Replacement
4. The brake hoses have banjo union fittings on each end. with the exception of the front master cylinder hose on XL600V-H to L (1987 to 1990) models and XRV750 models which has a hose joint piece, and the brake pipes have joint nuts securing them in their unions (see illustrations 7.6 and 7.7). Cover the surrounding area with plenty of rags and unscrew the banjo bolt or joint nut at each end of the hose or pipe, noting its alignment. On the front master cylinder hose on XL600V-H to L (1987 to 1990) models and XRV750 models, counter-hold the hose nut and unscrew the locknut and separate the hose from the hose joint in the caliper (see illustration 7.7). If required, unscrew the hose joint from the master cylinder. Free the hoses/pipes from any clips or guides and remove them. Discard the sealing washers as new ones must be used.
5. Position the new hose, making sure it isn't twisted or otherwise strained, and abut the tab on the hose union with the lug on the component casting, where present. Otherwise align the hose or pipe as noted on removal. Install the hose banjo bolts using new sealing washers on both sides of the unions. Tighten the banjo bolts to the torque setting specified at the beginning of this Chapter.
6. Locate the end of the new pipe into its union and tighten the nut securely, but not overtight.
7. On the front master cylinder hose on XL600V-H to L (1987 to 1990) models and XRV750 models, if removed, thread the joint piece Into the master cylinder using a new sealing washer and tighten it securely (see illustration 7.7). Fit the hose against the hose joint and tighten the locknut onto the hose, counter-holding the hose nut to prevent the hose twisting. Do not overtighten the locknut.
8. Make sure the hoses and pipes are correctly aligned and routed clear of all moving components. Flush the old brake fluid from the system, refill with new DOT 4 brake fluid (see Daily (pre-ride) checks) and bleed the air from the system (see Section 10). Check the operation of the brakes carefully before riding the motorcycle.