soft front brakes

'82 Maxim 650. I find that my front brakes are pretty soft , having to squeeze the brake almost all the way to stop.I also have noticed a fair amount of brake fluid on the disk. I'm not to mechanically inclined but I have done a fair amount of car work...Any ideas what the prob may be and where to start w/ it? Someone should start a video repair site so us newbies can watch the prof. do it! Thanks to all!

 

Sounds like the seals in the caliper are bad.

don't ride till that one is fixed

 

Time for a rebuild Rymadyl. Figure on purchasing caliper and master cylinder rebuild kits as well as new braided stainless lines. You will be best served (especially for the price) to upgrade to stainless as the rubber lines expand too easily and rot after about 10 years. Given the appearance of brake fluid on your disks, you will probably need new brake pads as well. Contact our resident parts guru Chacal for a quote. He's good with parts and knowledge.

 

When you replace your front brake lines (you have 2 - one upper and one lower) and the seals from the caliper (yamaha part# 2G2-W0047-00-00 includes 3 different parts) make sure to replace all crush washers with new ones. There are little copper washers that literally "crush" when tightened and act as a threadlocking seal for your brake line bolts. There are 8 total (yamaha part#: 90201-10118-00). Once you get all of your parts together I would use a hand bleeder http://www.amazon.com/gp/product/B000EVYGXC. Once you cause a suction then you open the bleeder valve and it sucks the fluid from the reservoir taking the air bubbles with it. Just remember you are forcing air bubbles down through both brake lines and joint coupler so it will take a long time. You can save time by removing the fuel tank and draining the carbs, then lay the bike over carefully on its side so the air bubbles don't have to fight their way down instead of wanting to naturally go up.

vman7mm

 

Also on the master cylinder rebuild kit is a must. But just a little advice when you get the kit the cylinder and the rubber ring are not together make sure to lube that rubber up with a little brake fluid before you try to slip it over the cylinder otherwise the rubber will snap.( sorry past experience) and you will have to shell out another 30 bucks for another one. Or if you get it from a local bike shop have them put it on so your not liable and they are. Good Luck..

 

My 81 650 has soft front brakes also, Where do you get stainless lines at. I was told Dennis Kirk has some that might fit. I'm going to get the kits from chacal when I place my next order.

 

I believe Chacal has stainless lines for most of the XJ models. Reasonable prices and I believe a selection of colors. I believe his assemblies are DOT approved too. The other guys are selling assemblies made from DOT components, but I don't believe the assemblies themselves have been tested to DOT standards.

 

Make sure it is not your seals from your fork leaking on to your disks.

My dog takes Rymadyl for her arthritis. What up?

 

LINES-R-US!

(and crush washers, too):

Our complete selection of STAR-6ZF BRAKE LINES are now available, in both the original style flexible black rubber hose or constructed using an advanced-design, high-performance braided stainless steel hose---an upgrade that will dramatically improve brake system feel and performance, and go a long way to bringing your bike up to modern-day braking standards.

And all of the STAR-6ZF brake lines are designed and custom-fit to exactly replace your original, model-specific brake lines in both appearance, fit, and especially function.

NOTE: our lines are the ONLY fully DOT approved brake hoses on the market. Other suppliers of brake lines---including the well-known "brand name" producers of such lines---are using DOT-approved rubber or stainless steel HOSE---as all manufacturers are required to use---but the completed BRAKE LINE ASSEMBLY is not DOT-approved.

To have a completed BRAKE LINE ASSEMBLY be DOT-approved for street use, each individual completed unit must be pressure-tested to 3000psi and pass a series of other tests. Only when EACH INDIVIDUAL UNIT OF PRODUCTION PASSES SUCH TESTS can that individual line get a DOT approval number die-embossed onto the end fittings.

Needless to say, all of our lines are tested, and therefore are approved by both the NHTSA and the DOT for street-legal use.


The Fine Print:

This is why, if you read the advertising claims of brake line manufacturers carefully, you may find the words "DOT-approved" being claimed in regards to the brake HOSE, but never to the completed brake LINE. This is the key difference that all the brake line builders realize, and take great pains to either hide or disguise..........either by stating that the HOSE (rather than the assembled LINE) is DOT-approved, or claiming that they are "approved for off-road use only".

But now you know better!



1980-83 XJ650 Maxim and Midnight Maxim models:

HCP2822RU Reproduction DOT-approved rubber BRAKE HOSE ASSEMBLY, from the master cylinder to the distribution joint on the lower steering bracket.
$ 34.95

HCP2823RU Reproduction DOT-approved rubber BRAKE HOSE ASSEMBLY, from the distribution joint on the lower steering bracket to the left front brake caliper. Includes the rubber sleeve grommet for the hose routing bracket.
$ 37.95



bhs1) Aftermarket high-performance BRAIDED STAINLESS STEEL BRAKE LINES, fully and completely DOT approved, pre-bent and configured for each specific model. Constructed with a PTFE Type 62 Teflon coated inner tube---therefore making these lines compatible with all types of brake fluid on the market today---and then wrapped with 16 layers of a braided stainless steel mesh, making them the finest quality and safest lines on the market today. These lines truly give you the best braking system enhancement for your money.

Our braided stainless steel brake lines are available with your choice of the protective, translucent plastic outer sheath color: Black (BLK), Bright Blue (BLU), Bright Red (RED), or Clear (CLR). Please note that the Clear (CLR) outer sheathing allows you to see the inner stainless steel braid directly, so that the hose appears like it is "silver" or "chrome".

All of our STAR-6ZF braided stainless steel brake lines come with the bright zinc-plated banjo end fittings already pressure-crimped to the hose, making the lines ready-to-install, as original (NOTE: some models may have originally had yellow-zinc plated banjo fittings, which are no longer available due to environmental considerations).

On models originally equipped with the outer coil spring armor, these replacement braided stainless steel lines will NOT have such spring-armor installed.....it is not necessary as the braided stainless steel mesh is far stronger and more puncture-resistant than the spring-armor ever was.

All caliper lines also come with an attached hose routing bracket rubber grommet that is similar to the original.

NOTE: because our lines have been designed and test fitted on ORIGINAL BIKES, they may not fit well or at all on bikes that have been modified from original via the use of these different major components: forks, fork tubes, brake calipers, steering under-bracket or crown bracket, handlebars, or master cylinders. Braided stainless steel lines have very little (meaning: "zero") rotational flexing ability, and thus once their end fittings are bent and oriented to a specific application---such as with our lines---there's not much end fitting orientation variance (from original) available----unlike with our rubber lines, which have a much greater range of flexibility to them.

Also, please be aware that braided stainless steel lines will give you a much firmer lever feel and quicker, more precise and responsive braking action. You will need to get accustomed to the new braking characteristics of your bike in a controlled manner: practice makes perfect. Trust us---you do NOT want your first real "practice" session to involve a panic stop!

Finally, since stainless lines have almost no "pressure swell" to them AT ALL, it is not uncommon that any brake disc rotor warpage issues.....even minor ones.....that were previously unknown or minor in effect while those old, worn rubber lines were installed, will become HIGHLY NOTICABLE when you install stainless steel lines. There will no longer be any "swelling, pulsating, deteriorated rubber hoses" to absorb all those tiny pulses of fluid pressure that a warped rotor(s) causes.....and you WILL feel these pulses (in the lever, and in the brake system action) with a stainless brake line installed!

Now, give this idea some thought: with new braided stainless steel brake lines, a rebuilt master cylinder and rebuilt caliper(s), and with a replacement high-performance EBC high-performance bolt-on disc brake rotor and brake pads (or two, or three, depending on your model)---could it be that all of a sudden, your 20+ year old XJ-series bike now stops just as well as a modern bike?


1980-83 XJ650 Maxim and Midnight Maxim models:

NOTE: on these models, the caliper line includes the rubber sleeve grommet for the fender hose routing bracket.


HCP2822BLKST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with black sheathing.
$ 44.95

HCP2823BLKST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with black sheathing.
$ 47.95



HCP2822CLRST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with clear sheathing.
$ 44.95

HCP2823CLRST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with clear sheathing.
$ 47.95



HCP2822REDST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with bright red sheathing.
$ 44.95

HCP2823REDST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with bright red sheathing.
$ 47.95



HCP2822BLUST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with bright blue sheathing.
$ 44.95

HCP2823BLUST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with bright blue sheathing.
$ 47.95



Union "Banjo" Bolts:

HCP1075 OEM brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. This is a single-hose-attachment length bolt, dark phosphate finish, and is used on all models, in all positions, except for the models/positions listed as using a double-hose-attachment length bolt under part number HCP1076 below. These bolts should be tightened to a maximum of 19 foot-pounds of torque! Each:
$ 2.00

HCP1075SET2 OEM brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 2:
$ 3.75

HCP1075SET4 OEM brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 4:
$ 7.25

HCP1075SET8 OEM brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 8:
$ 14.00




HCP4232 Aftermarket brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. This is a single-hose-attachment length bolt, bright polished chrome-plated finish, and is used on all models, in all positions, except for the models/positions listed as using a double-hose-attachment length bolt under part number HCP1076 below. These bolts should be tightened to a maximum of 15 foot-pounds of torque! Each:
$ 5.00

HCP4232SET2 OEM brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 2:
$ 9.00

HCP4232SET4 OEM brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 4:
$ 17.00

HCP4232SET8 OEM brake hose junction Union Bolt, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. Set of 8:
$ 29.00


TOTAL SINGLE-DEPTH UNION BOLT USAGE BY BIKE:

XJ550 all models (use 4)
XJ650 Maxim and Midnight Maxim (use 4)
XJ650RJ Seca (use 6)
XJ650 Turbo (use 6)
XJ700 all (use 4)
XJ750J (1982) Maxim (use 6)
XJ750K (1983) Maxim and Midnight Maxim (use 4)
XJ750 Seca (use 4)
XJ900RK (use 6, front)
XJ900RK (use 2, rear)
XJ1100 (use 4, front)
XJ1100 (use 3, rear)



Crush Washers:

HCP1077 OEM brake hose union bolt copper Crush Washer, used to seal the brake hose end fitting to both the union bolt and the attachment point (be it the master cylinder, the distribution block, the lower fork tube, or the caliper). Each single-length union bolt requires the use of two crush washers, while double-length union bolts requires the use of three washers per bolt. Crush washers should be replaced every time you remove a brake hose!! NEVER use any other type of washer in place of a crush washer!!! Each:
$ 1.50

HCP1077SET2 OEM brake hose union bolt copper Crush Washer, pair:
$ 2.95

HCP1077SET4 OEM brake hose union bolt copper Crush Washer, set of 4:
$ 5.75

HCP1077SET8 OEM brake hose union bolt copper Crush Washer, set of 8:
$ 11.00

HCP1077SET12 OEM brake hose union bolt copper Crush Washer, set of 12:
$ 16.00

HCP1077SET24 OEM brake hose union bolt copper Crush Washer, set of 24:
$ 30.00



HCP4231 Aftermarket brake hose union bolt copper Crush Washer, used to seal the brake hose end fitting to both the union bolt and the attachment point (be it the master cylinder, the distribution block, the lower fork tube, or the caliper). Each single-length union bolt requires the use of two crush washers, while double-length union bolts requires the use of three washers per bolt. Crush washers should be replaced every time you remove a brake hose!! NEVER use any other type of washer in place of a crush washer!!! Each:
$ 1.25

HCP4231SET2 Aftermarket brake hose union bolt copper Crush Washer, pair:
$ 2.25

HCP4231SET4 Aftermarket brake hose union bolt copper Crush Washer, set of 4:
$ 4.00

HCP4231SET8 Aftermarket brake hose union bolt copper Crush Washer, set of 8:
$ 7.00

HCP4231SET12 Aftermarket brake hose union bolt copper Crush Washer, set of 12:
$ 9.00

HCP4231SET24 Aftermarket brake hose union bolt copper Crush Washer, set of 24:
$ 17.00


TOTAL BRAKE CRUSH WASHER USAGE BY BIKE:

XJ550 all (use 8)
XJ650 Maxim and Midnight Maxim (use 8)
XJ650RJ Seca (use 12)
XJ650 Turbo (use 12)
XJ700 all (use 11)
XJ750J (1982) Maxim (use 12)
XJ750K (1983) Maxim and Midnight Maxim (use 11)
XJ750 Seca (use 14)
XJ900RK (use 8, front)
XJ900RK (use 4, rear)
XJ1100 (use 11, front)
XJ1100 (use 6, rear)




Brake System Tools:


bp1) Master Cylinder DEEP-REACH CIRCLIP PLIERS----these special extra-deep 90-degree angled circlip pliers allow you to easily remove and install the circlip (or "c'-clip) that hides way down inside the top of the plunger bore (below the rubber boot). Without a DEEP set of circlip pliers, you're going to fight and struggle with this part of your master cylinder rebuild project. Regular store-bought circlip pliers may have a 90-degree attachment, but unless they are extra-deep like these, they still won't be able to reach that circlip.

HCP1597 Aftermarket master cylinder Circlip Pliers, each:
$ 16.95



bp11) Aftermarket BRAKE BLEEDER KITS. By eliminating the need to constantly pump-and-release the hand lever, and loosen and tighten the bleeder screw, you'll save yourself an incredible amount of time, effort, and swearing with these kits.

The master cylinders on these bikes push a very small amount of fluid with each hand stroke, and thus bleeding a system is a long, time-consuming chore----but, on the positive side, it's a really great way to build up a really strong, firm, manly handshake and grip. But there's other ways and times to accomplish that, so when all you want to do is bleed your brakes, then there's nothing better than these labor-saving tools.

NOTE: hand-bleeding a dry system...such as when you change brake lines, or have rebuilt the master cylinder or calipers....is next to impossible to do without the use of a Mity-Vac vacuum system. It will take you hours to do by hand. With a Mity Vac, you'll do it in about 10 minutes, tops.

The one-way valve kit is recommended for bleeding already full systems during annual fluid changes, etc.

Hints: Make sure you don't run out of fluid in the reservoir when using these tools!

Also, make sure that your caliper bleeder screws are clean and pass fluid freely (and continue to do so once the system is evacuated) as old debris in your brake system settles down to the lowest point in the system (the caliper reservoir) and gets sucked into the bleeder screw during bleeding, this clogging the system and making it impossible to bleed.


HCP5908 All hail the great MITY-VAC vacuum assisted brake bleeder system. This complete kit contains the patented Mity-Vac vacuum-assisted brake bleeder vacuum pump, a fluid cup with bleed and storage lids, and assortment of clear hose lengths, adapters, and instruction manual.
$ 39.95


HCP8546 Aftermarket ONE-WAY VALVE BLEEDER HOSE KIT. The principle behind this simple device is just like the Speed Bleeder screws listed previously: a pressure-controlled one-way valve allows fluid out, but snaps shut to prevent air from rushing back in....thus allowing one person to easily bleed their brake system. Just release your standard brake caliper bleeder screw, install the clear tube over the fluid port, and begin pumping the lever. Nowhere near as quick and easy as the Mity-Vac listed above, but a very useful alternative to the muscle cramps you'll get trying to bleed your system using the old-fashioned (two-person) method. Instructions included. NOT RECOMMENDED FOR USE ON EMPTY (DRY) SYSTEMS!
$ 16.95



1980-83 XJ650 Maxim and Midnight Maxim models:

NOTE: on these models, the caliper line includes the rubber sleeve grommet for the fender hose routing bracket.


HCP2822BLKST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with black sheathing.
$ 44.95

HCP2823BLKST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with black sheathing.
$ 47.95



HCP2822CLRST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with clear sheathing.
$ 44.95

HCP2823CLRST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with clear sheathing.
$ 47.95



HCP2822REDST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with bright red sheathing.
$ 44.95

HCP2823REDST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with bright red sheathing.
$ 47.95



HCP2822BLUST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the master cylinder to the distribution joint, with bright blue sheathing.
$ 44.95

HCP2823BLUST Aftermarket DOT-approved braided stainless steel BRAKE LINE ASSEMBLY, from the distribution joint to the left brake caliper, with bright blue sheathing.
$ 47.95