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Picture needed for stock routing of brake lines and main wire harnesses

Discussion in 'XJ Technical Chat' started by SecaMaverick, May 3, 2018.

  1. SecaMaverick

    SecaMaverick Active Member

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    Can anyone with a stock '81 XJ550RH Seca please snap a couple pics of the front brake joint/manifold area under the chrome Yamaha fork emblem? I'm taking my bike back to stock (two brake lines with manifold), replacing the PO's single brake line and no manifold. It's been this way since I bought it in 2001.

    When I'm bolting the new manifold on underneath the chrome Yamaha fork emblem, that area seems cramped because both main wiring harnesses pass up and around the same area on their way to the headlight. Not sure if that's right or not, and if not, how should it be? Hoping a couple pictures will help. Pics of the area in question may have existed in BigFitz's brake-line replacement write-up at one time, but since the Photobucket fiasco, none of those pictures display.
    Thanks in advance.
     
  2. XJ550H

    XJ550H Well-Known Member Premium Member

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    no pics of that type in the Bigfitz post, will post some photos today for you
     
    Last edited: May 4, 2018
  3. XJ550H

    XJ550H Well-Known Member Premium Member

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    [​IMG]

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  4. XJ550H

    XJ550H Well-Known Member Premium Member

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    SecaMaverick likes this.
  5. SecaMaverick

    SecaMaverick Active Member

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    Perfect, thanks! Looks like I'll need to come up with a harness wire "loop hook" to bolt up to the same bolt that holds the brake union/manifold. Never had one of those, either.
    Appreciate your help, XJ!
     
  6. XJ550H

    XJ550H Well-Known Member Premium Member

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    Last edited: May 7, 2018
  7. SecaMaverick

    SecaMaverick Active Member

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    Thanks again for your help, XJ! Just to follow up after the brake line replacement: your pics helped get things routed pretty close to stock.

    The non-stock Clubman handlebars on my bike (added by the PO a couple decades ago) prevented me from routing the new top stainless brake line inside of the headlight bracket as original would be. The line kinked too much at the brake union/manifold because of the slightly different twist. But aside from a couple minor leaks during bleeding that I remedied by further tightening the four new banjo bolts with new washers, I'm very pleased with how things went together.

    I went ahead and also repainted and rebuilt the caliper as well (freshly honed, and with new seals and piston). I borrowed a buddy's brake bleeder -- which saved a TON of time -- and the lever feels great.

    Looking forward to getting it back on the road.
     

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