Brake line through the swingarm query

[Zanderk]

Hi All, this weekends job is the brake line swingarm mod and I’ve read as many posts on this to try and build up an idea of the whole process. I brought a brake line kit from Hord in readiness. Now although the banjo comes apart, it leaves a female internally threaded part of the banjo on the line. This is obviously wider than the standard brake line and so would mean a bigger hole needs drilling to accommodate it.
Now I can’t see anyway to remove the female connector and then just push the brake line through, so here’s my question ;

Have others just drilled a larger diameter hole (12mm or so I’d say or 1/2” in old money) or is it better to cut the line, get some new fittings and rebuild the line once it’s in situ ?

Just interested in the what others have done as don’t want to make a mistake here.

Thanks as always ;

[69Falcon]

Drill a slightly bigger hole and add a grommet.

[Zanderk]

I know to all of you very experienced Hawkers who have been round the block it seems like a trivial and simplistic question but despite a lifetime on and around road and race bikes, I have never drilled a swingarm, hence the caution. Drill a hole too big and you ain’t easily putting it right again. Yep have a drill bit and a grommet already measured up so I’ll go with that.

[JackalHack]

That is what I did - hole in the circle that seems to be right there, hole in the rubber gasket-type thing at the front. Worked great!

[6]

Did you get this done last weekend?

[Zanderk]

Did you get this done last weekend?

Thanks for asking

I did indeed and I never realised how much effort would be required to drill the swing arm. Crumbs. Took a long time for the first pilot hole ! Happy with the result. This weekends project is making a CRF 250 integral rear brake reservoir / master cylinder fit the Hawk mountings (similar piston diameter). Again a lot of drilling aluminium and out with the rat tailed file !

[6]

Thanks for asking

I did indeed and I never realised how much effort would be required to drill the swing arm. Crumbs. Took a long time for the first pilot hole ! Happy with the result. This weekends project is making a CRF 250 integral rear brake reservoir / master cylinder fit the Hawk mountings (similar piston diameter). Again a lot of drilling aluminium and out with the rat tailed file !

Nice... THe Line through the arm is one of the best mods for making a hawk look "clean". havent seen the crf MC mod... I tend to remove the rear brake. Post pics when its done!

[Zanderk]

Nice... THe Line through the arm is one of the best mods for making a hawk look "clean". havent seen the crf MC mod... I tend to remove the rear brake. Post pics when it’s done!

Yep will do. The master cylinder I got is a bag of crap so I need to fully recondition it before mounting it on the bike and trying it out. I also need to work out the ratio between master cylinder piston diameter vs. Brembo P32F. Thought it was going to be similar to the existing Hawk but obviously a bit of variation between CRF models (what I got wasn’t from the model / year that was advertised - one of them). I’ll keep you all posted on the outcome

[bezier_kid]

AHRMA guys laughed at the stock brake line routing.

[Toxicwst]

...This weekends project is making a CRF 250 integral rear brake reservoir / master cylinder fit the Hawk mountings...

OOoooooh..... that sounds like a fun bit of modification! Would love to see pictures of the final outcome and processes. (Thumbs up!)

[Zanderk]

OOoooooh..... that sounds like a fun bit of modification! Would love to see pictures of the final outcome and processes. (Thumbs up!)

Well the master cylinder arrived and I got it to fit however the unit itself was corroded on some of the fittings and the master cylinder diameter which I expected to be 12.7 (ala Hawk I believe) turned out to be 10.5, which means my master cylinder : piston ratio will be out. All the joys of modification