XS650 project

Before rebuilding and painting the calipers I wanted to sort out a way to simplify the brake lines. The stock '75 XS650 front brake line goes from hose to hard line, then the junction block and pressure switch, hose again and then back to hard line at the caliper.
100_8568

Since the early two piston caliper doesn't use a regular banjo fitting, I'm using Russell adapters part # R41431 at the calipers. These come 2 to a package.
100_8543

100_8590

The nut portion of the adapter is bigger than the stock brake line and makes slight contact with the caliper.
100_8579

The little ridge is where it touches...
100_8573

...so just needed hit with a die grinder.
100_8582

Now it fits without contact. This will let me use a standard braided brake line with 10mm banjo fittings at one end and -3 AN female at the caliper, eliminating the hard line. The stock single caliper master cylinder is 16mm, and the European market twin disc models are 22mm. These calipers have 48mm pistons, and according to the Vintage Brake chart it looks like 19mm(3/4") should be a good choice. I need to get one with the brake light switch built in, which will get rid of the pressure switch.
100_8586

No comments: