2002 Brake lines - what to buy after removing servo

[Bikermike1411]

Hi all,

Can someone please help me out here!

I've removed the ABS servo from my 2002 (52 reg) 1150GS, I was just going to use the existing brake lines reconfigured by removing the tab off the connector piece and rotating it to suit. However, the ends of the hoses are in poor condition, so i'd like to replace them with braided ones. However, I really can't work out exactly which hoses to buy!

Do I need 'ABS + SERVO' hoses (because mine did have this) to ensure everything reaches (i.e. from the master cylinder to the splitter, then down to the bridge piece) and also that the hose ends will be the correct angle for the calipers, or do I now need 'non-ABS kit?

I can't understand why noone makes a kit which just goes straight from the master cylinder to the fork bridge piece, then directly to each caliper from there. Surely there's enough cause to do this owing to the number of people removing servos etc.

I've been trying to get my head around this for a week now - should have probably just asked the collective sooner!

Cheers
Mike

 

[Bikermike1411]

I suppose another question is what’s the difference between the hoses on the ABS+servo and non-ABS+servo hoses. Is it the hose length, or do they have different calipers meaning the banjo angles might be different?

Can I put hoses for a non-Abs model on mine following the servoectomy?

Also, do non Abs/servo models have a union bolted to the headstock and if so am I better sourcing one and converting to a fully oem non-abs setup?

Cheers
Mike

 

[Neil W]

Try HEL website or measure them and make your own with Goodridge Build a Line parts alternatively buy a pre built kit for the non abs equivalent of your year of bike/ caliper combinations .
Then if you need alternative lines make them up.
Another alternative is ring up Motorworks if you do a google search they advertise Goodridge lines for bikes with ABS removed

 

[Bikermike1411]

Thanks Neil. I’ve used HEL on all my other bikes, but at £180 just for the front lines they’re not cheap for a GS.

Do you know if there’s any difference between ABS and non-ABS lines?

I know I can pick up the Venhill non-ABS kit about 30% cheaper than the HEL abs one.

 

[Bikermike1411]

Right, I think I’ve sorted it.

Looking at the fische, the non-servo bikes do have a single pipe to the solid mudguard bridge pipe. The part number for the bridge is the same for any bike, so the only difference is the pipe from the master cylinder to the bridge (the smaller one below is a fixed length, I’m ignoring that). This means that all I need is the non ABS setup.

Also, there’s a HEL franchise on eBay offering ‘simplified setup’ kits. I’ll see what they say!

 

[DrFarkoff]

Yeah the NON ABS go from the Master cylinder to the alloy "manifold" on the headstock and down

And from the Rear master straight to the calliper

You could buy the manifold and use what you have fitted up front already

and a rear pipe 34327651643 Just double check that number before ordering there's a good chap




and the "manifold" Part 9 34327650965

 

[Wrigsby1]

Easiest is a standard set of braided servo hoses for the front and the little joiner that Motorworks do... You can make your own but why bother if you haven't the tools .. Rear one is an non servo braided hose that Motorworks also do... I've fitted this kit myself twice and if you stick with standard fits it is less buggering about...

 

[Bikermike1411]

What do you call ‘standard’ Wrigsby? Just the ‘ABS+Servo’ versions, then join them at the headstock with either the existing union (rotated) or with a Motorworks version?

 

[Bikermike1411]

Yeah the NON ABS go from the Master cylinder to the alloy "manifold" on the headstock and down

And from the Rear master straight to the calliper

You could buy the manifold and use what you have fitted up front already

and a rear pipe 34327651643 Just double check that number before ordering there's a good chap

View attachment 527817


and the "manifold" Part 9 34327650965

View attachment 527821

Cheers Dr F. So, is the only difference the manifold shape?

If I get non ABS lines and a manifold, it should all go together sweetly?

 

[Wrigsby1]

What do you call ‘standard’ Wrigsby? Just the ‘ABS+Servo’ versions, then join them at the headstock with either the existing union (rotated) or with a Motorworks version?

If you go for a braided set you are easiest the servo kit and the little copper u bend... Same fittings, straight replacement and the same as all the Adventures... Might be paying for one more line but the fit is simple and there will be no difference in the end...
Buying like for like kits is much easier than trying to measure you own plus fittings and angles...

 

[DrFarkoff]

If you go for a braided set you are easiest the servo kit and the little copper u bend... Same fittings, straight replacement and the same as all the Adventures... Might be paying for one more line but the fit is simple and there will be no difference in the end...
Buying like for like kits is much easier than trying to measure you own plus fittings and angles...

Cheers Dr F. So, is the only difference the manifold shape?

If I get non ABS lines and a manifold, it should all go together sweetly?

You do not need New lines unless yours are damaged !! The alloy manifold makes things so much nicer than those stupid Copper U bends

And the rear pipe just goes in place of what was there

If its a 1200 You just buy a different section of hard Brake line from the dealer and reuse all OE lines

 

[Bikermike1411]

Yeah, problem is my banjos at the end of the lines to the calipers are red rust, so I need to replace them. Just trying to work out what kit to buy, and what the ‘best’ way of doing it is

 

[Wrigsby1]

I'll stick out of it and leave it to the experts...! The OP had said his original lines were wanting replacement etc etc etc etc....

 

[Bikermike1411]

hah! It’s ok bud, I’m here for any and all advice!

 

[DrFarkoff]

I'll stick out of it and leave it to the experts...! The OP had said his original lines were wanting replacement etc etc etc etc....

No offence meant @Wrigsby1 Old bean I never even realised I had captured yours as a quote it was only supposed to be the OP

But I did get one of the dopey u bend things for a client and it just did not look right and suggested the OE Mainfold and they went for it

 

[DrFarkoff]

Yeah, problem is my banjos at the end of the lines to the calipers are red rust, so I need to replace them. Just trying to work out what kit to buy, and what the ‘best’ way of doing it is

See if anyone breaking one on E bay or whatever will sell you the front lines off a Non ABS one ??

I don;t think I have seen them rust except the old original Rubber type hoses ??

In which case You need to check, the upper hose to the manifold as it can start to bulge where it flexes at the headstock!!

@Steptoe published a warning about this a few years ago

 

[Bikermike1411]

This is one of them - trust me, that’s not just crud. The bike was used for commuting all year round - salt has corroded them badly. I’ve stripped them back to metal and cleaned the rust off. I could spray them black, but it wouldn’t last (especially as brake fluid is the best paint stripper known to man!). I’m happier just replacing them.

The upper hoses seem fine, but they’ll all be replaced with stainless ones.

 

[Udders]

View attachment 527885View attachment 527885

This is one of them - trust me, that’s not just crud. The bike was used for commuting all year round - salt has corroded them badly. I’ve stripped them back to metal and cleaned the rust off. I could spray them black, but it wouldn’t last (especially as brake fluid is the best paint stripper known to man!). I’m happier just replacing them.

The upper hoses seem fine, but they’ll all be replaced with stainless ones.

Lordy!
They absolutely need changing!

 

[Bikermike1411]

Hah! The bike is being restored - they were nasty, but could have been ok. 24 years old though, not worth worrying about, just change them for new ones

 

[DrFarkoff]

View attachment 527885View attachment 527885

This is one of them - trust me, that’s not just crud. The bike was used for commuting all year round - salt has corroded them badly. I’ve stripped them back to metal and cleaned the rust off. I could spray them black, but it wouldn’t last (especially as brake fluid is the best paint stripper known to man!). I’m happier just replacing them.

The upper hoses seem fine, but they’ll all be replaced with stainless ones.

Yeah Old rubber ones!

Was this a servo ABS system ??