Over the summer it was time to pay some attention to the front brakes of the trusty 1977 Honda CB550K. The outer brake line had cracked. There must be an inner hose as well, because no fluid leaked out, but it was still rather nerve wracking to see. Add in a very mushy lever feel, and it was time to replace some parts.
I decided to go with a stainless steel braided line. Stainless steel lines add firmer braking because they don’t expand and contract the way rubber hoses do. With only a single solid brake disc on the front, any added braking power is welcomed. I kept the stock master cylinder, caliper and the pads on the bike still looked good. I replaced everything in between the master and the caliper.
The stock setup consists of, starting at the master cylinder, a length of line that goes behind the headlight bucket, into a block. This block is where the wiring for the brake lights ends. Then from this block, another length of line runs down the fork leg to a solid piece of tubing. The solid piece of tubing makes a bend and then goes into the caliper.
In this photo you can see the wiring block and the solid tubing that runs into the caliper, both outlined by yellow boxes.
I didn’t care for this setup at all as there are two extra places for leaks to appear. I decided to do away with this setup entirely, and replace it with one solid length of line.
I got all parts at Dennis Kirk. I shopped there because not only did I previously work there, but they had everything I needed, fast & free shipping, and helpful staff – especially Tim in tech support. He’s the one who helped me put this list together.
- Part #198392 – 32″ Goodridge Platinum Universal Brake Lines w/Chrome-Plated Ends
- Part #191350 – Russell Brake Line Fitting-3/8 in.-24 Inverted Flare-#3 Straight
- Part #191339 – Russell Brake Line Fitting Chrome 3/8 in. /10mm Banjo x #3 Male 90°
- Part #210369 – K & S Hydraulic Brake Light Switch
- Part #27487 – Russell 10mm Aluminum Banjo Bolt Washers
- Part #303574 – Castrol GT LMA Brake Fluid
The brake light switch replaces the normal bolt that goes through the banjo into the master cylinder. This switch bolt has a length of wiring that I ran down with the new brake line, then plugged it into the wiring under/behind the headlight bucket for the brake light. The brake line then runs the entire route down the fork leg, and the small Russell brake line fitting connects the line to the caliper.
NOTE: Make sure you take a measurement of your current brake line. I have a set of drag bars installed, lowering bar height a couple inches. If you have stock or higher bars, you might need a longer brake line than the 32″ one I purchased.
After installing all parts, bleeding the line and testing it out, braking power and feel is much improved. It’s still not modern day bike with dual front wave rotors, but it’s a vast improvement over what was there. I’ll add some photos of the new setup soon. Hopefully this weekend the weather will be nice and I can get some good shots outside.
Hope this helps,
Jeff
8 Comments
Hi Jeff .. .Robb here, from up in Milwaukee. Found your CB550 brake upgrade recently, very helpful; I ordered the same parts from DK, and all’s well excepting that the adapter fitting that threads into the caliper has the wrong sized threads on it. I was just wondering whether you ever got your bss line installed, and whether you ran into that issue? Thanks in advance.
Hi Robb,
Thanks for the comment!
I double checked the parts I ordered, and I assume the part in question is Dennis Kirk part number 191350? I found the package in my garage, and that’s the one I ordered, and it did work. I had no leaks and my braking power was vastly improved. Maybe the threads are different across different years of the CB? If you call Dennis Kirk tech support – try to get Tim on the line. He knows his stuff, and originally helped me put the list together.
Jeff
Sounds like a good installation. I was wanting to do something similar with my ’76 550. Do you have a picture of the new installation?
Thanks,
Steve
Steve, I’m sorry but I can’t seem to locate photos. And I’ve since sold the CB550, so I can’t shoot some now. Shoulda kept it though; it was a fun old bike.
If you have particular questions about the install post them up and I’ll answer them as best I can.
Jeff,
Thanks for posting this, I called Tim at Dennis Kirk and he reassured me that the parts would work, he remembers you and several other asking the same questions.
Very cool.
Thanks.
Great! I’m glad my post helped you. Tim is a good guy and really knows his stuff.
I just wanted to say Thanks.
I ran into the same problem as Robb. The original fitting that threads into the caliper has a courser thread than the Russel fitting from Dennis Kirk. I’d imagine it’s a metric thread and the Russel fitting is standard (non-metric). I’m thinking about taking the metric fitting off the original line and installing it on the Russel line to keep the flared fitting on the other end.
Thanks again for the good info.
Steve