Brake Line Availability

Where can I get replacement rubber brake lines? I recently disassembled my front master cylinder and calipers, cleaned them out, and re-assembled. I am having trouble getting the system to bleed properly, and I'm suspecting the 30 year old lines. Are brake lines generic like spark plugs? I.e. instead of needing a KZ650 specific brake line, I need a brake line of x length and y diameter with z fittings? If so, who sells lines at a decent price?

Thanks.

www.spieglerusa.com/cfm/brakelines.cfm

Hey bemore. I priced out original lines from Kawasaki and instead decided to put Russell stainless braided lines on my '77 Kz650/810. I ordered them from my local bike shop and each of the three lines set me back about $35 including the banjo bolt fittings. With the Russell lines you can order the exact length in one inch increments, and boy do they look trick. Give your friendly local bike shop a call or touch base with Jeff @ Z1 Enterprises.

Cheers-Colin Firth-Ontario Canada
1977 Kz 650 Custom with 14,000 original miles. Bought new by my brother in '77. Latest incarnation includes 810 Wiseco kit, WG Mikuni 28's, Velocity stacks, ported, polished and milled Kz 650 head, 750 cams, intake valves, Gpz springs. Dyna Ignition and coils, MAC pipe, 130 rear tire, stainless brake lines, 14 tooth sprocket. Next step is a custom aluminum swingarm and nitrous.

btchalice wrote:

www.spieglerusa.com/cfm/brakelines.cfm

Like Old Bike Barn, they incorrectly list three brake lines for the front of the 650 B2-B3 models. I don't know where they got their information, but it's maddenly incorrect!

- Nate >>

I got the Russel lines on mine too, they not only look trick but they eliminate the spongy feel the stock lines have.
I got mine off ebay from a guy selling a set of calipers for $10 and the lines were included :whistle:

Say, Wicked, can you tell me what the length of the banjo ends are? The length of the hose pieces are listed in the catalogs that I've found, but nothing is said about the length about the banjos. I assume that the hose measurements provided are from the outer end of each female coupler.

Maybe I'm being too careful here, but I don't want to by things and wind up an inch short or have to deal with a few inches of excess. I'd like to land at stock length to maybe a half inch longer if possible.

For reference, here are my measurements for my KZ650B3:

Upper: 18.75" tip-to-tip 30 deg at master cylinder, straight at pressure switch
Lower: 14.75" tip-to-tip 30 deg at each end

- Nate >>

The parts I bought off ebay were off an 81 GPZ 1100 and the lines bolted right up (I figured for $10 if things didn't fit I wasn't out too much money so it was worth the risk). The line from the master cylender to the manifold was about an inch longer than the original but it fit nicely after re-clocking it and tightening the banjo bolt. the other 2 lines were a little shorter than my stock lines (about an inch shorter) but still not a problem at all since there was still quite a bit of slack in them with the suspension fully extended.

Measuring mine accurately would be very difficult with them installed because the line from the master cylender was excessively long and needed a good S bend to it so it would sit in place without any problems and still be hidden well.

the banjo ends on mine are 2" from tip to the swedge end on all my fittings. All the banjo ends are straight except for the 30 degree bends at the fork manifold going down to the calipers. All 3 lines have the banjo fittings swedged 90 degrees from the opposite end for proper fitment.

if you can do without your bike for a week or 2 it would still be best to send them your original lines so they can duplicate them exactly.

By swedge end, I presume you mean up to, but not including the female ferrel nut on the hose? Since I have one line that measures 14.75" end-to-end, I would probably need a 12" line as a 9" would be too short (the next shorter). As I say, I'm probably being too careful.

I'm still hoping to have a chat with the line maker for Old Bike Barn (we're playing phone tag) and give him all the specs. The only disrepenancy that really exists is that OBB has a three line kit for the 650B2/3 when even the Kawasaki parts book only shows two. I don't really need a spare, do I? :whistle:

- Nate >>

Okay, I got the new lines today. I ordered them through Old Bike Barn after talking to Craig of HelUSA on Monday morning (he makes their brake line kits). The kit is first rate and includes not only the lines but the banjo bolts, crush washers, and an insert with torque specs and bleeding tips.

I posted pics and a more detailed writeup over on kz650.info .

I look forward to seeing how they perform on the road.

- Nate >>