Kawi2strokes.com Forum

Hello all, I am converting my front caliper to an ex500. I already have it mounted using Evan's adapter. The question I have is how do you handle the brake line? I already had a SS line from the junction box to the old caliper hard line but now I need a flexible line from the end of the old SS flex line to a banjo fitting on the ex500 caliper. These things are pricey so I am wondering if it might be more cost effective to run an entirely new line from junction to caliper. Also, the banjo fitting at caliper looks to be angled up and/or sideways?
TIA,
Jim

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Jim
Atlanta, GA
1974 H1
1976 KZ400
1979 XS650 Cafe
1982 GPz750
2001 KZ1000P
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it; it's not really yours"

The common solution is what I did... get a 1/2" master cylinder with a built in brake light switch, and run a stainless braided line from the master cylinder directly to the caliper.

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If it surges, that's normal, upshift.

Hmmmm. I had not considered that. Is the Ex500 front master 1/2"? I wonder if the stock front line would work on my H1? I'm running superbike bars.
Edit: looked on eBay. The Ex500 masters I saw don't have a mirror mount.

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Jim
Atlanta, GA
1974 H1
1976 KZ400
1979 XS650 Cafe
1982 GPz750
2001 KZ1000P
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it; it's not really yours"

Oh, right... I have bar end mirrors.

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If it surges, that's normal, upshift.

You can get a 1/2 inch master cyl. off E-bay, etc, with a mirror mount and brake-light switch, cheap and easy. I mean, I have one, can't be hard to find!

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"One day, your life will flash before your eyes. Make sure it's worth watching." : anon.

If you are doing any “real” riding never go “cheap & easy” when it comes to brake parts. Always go OEM.

I'm actually going 'relatively inexpensively' and 'straightforward in installation'. Good luck finding a new OEM Master cylinder! I have done just a little bit of "real" riding over the years.....!

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"One day, your life will flash before your eyes. Make sure it's worth watching." : anon.

When I did the EX conversion on my H1 I bought a caliper with master cylinder still connected by the original hose. This way there is much less chance of either being blocked up with crud or corroded as long as it is still a sealed system. (still rebuild both, and new stainless hose...) It also gives the advantage of ensuring compatibility. I also bought the matching clutch perch, both with mirror mounts and those nice dog leg levers, just gives it a cleaner look to me. I did have to pull 2 wires through the sleeve from the brake light switch (now on the M/C) to the connectors where the old switch is, but most will never notice.

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We don't need no stinkin' Cams!

Not opposed to changing out the MC since I always felt it was a little mushy even with the SS braided lines. It might be the most cost effective in the long run.

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Jim
Atlanta, GA
1974 H1
1976 KZ400
1979 XS650 Cafe
1982 GPz750
2001 KZ1000P
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it; it's not really yours"

You need a 1/2" master cylinder to take advantage of the EX caliper, so stock isn't ideal. Some of the mushy feel comes from the junction with the pressure switch, since it needs some fluid to activate the switch.

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If it surges, that's normal, upshift.