How to Replace Motorcycle Brake Lines

Lead Image
  • 1-2 hours
  • Beginner
  • 10-25
What You'll Need
Screwdriver set
Socket set
Washer pack
Torque wrench
Brake fluid

There are so many reasons why you may have to replace your motorcycle brake lines at some point. If you get into an accident, the hose kinks or your motorcycle experiences just normal wear and tear, you may find yourself having to do this replacement on your own. Here are a few tools that you may need as well as some steps that can help guide you through the process with ease.

Step 1 - Prepare

Begin by putting the pan under the caliper so that you can catch anything while working. Then use a clean cloth or rag to wipe down the master cylinder. Use clean rags to cover up some of the parts including the fuel tank, the handlebars and the fluid reservoir.

Step 2 - Remove Fittings

Begin this step by removing the banjo bolt that is holding hose on the caliper. Use a ratchet and a socket to remove the bolt. Now you will be able to access the old crush washers and you can take those off and get rid of them. Then use the lever on the brake to remove all of the fluids from inside. This may take a few minutes and it will drain into the catch pan that you have already set up.

Step 3 - Replace Fittings

Now you can put the new replacement washers on where you took the old ones off. Next, replace the bolt that you removed and use a wrench to tighten it a little, but you do not want it to be on all of the way just yet. Now is the time to add the brake fluid into the reservoir and then pump the brake handle until you can see that the fluid is coming through. Check your manual during this section of the task because some models with differ with how this part is done. Once you have finished adding the brake fluid though, you can reattach the brake line supports and be sure that they have been tightened. Make sure that you use a rag to clean up any of the fluid that may have gotten all over while you were working. This can happen especially if you are new to the task and have never performed it before.

Step 4 - Finish Up

Once you are finished with that part you will want to fill the reservoir with fresh new fluid and check the amount of time that is needed to bleed the brakes for your make and model motorcycle. Depending on the model it will vary slightly and you will want to make sure that you have the right times and methods. Let the brakes bleed for the allotted amount of time for your motorcycle.

When you are finished make sure that you test out the bike when you are in a small and quiet area in case there are any problems. Do not wait until you are driving on the highway to test.