Brake Line Replacement

The brake system uses plastic-coated steel lines as rigid connections. Flexible hoses connect to the front and rear wheels. Replacing lines and hoses requires specific experience.

* When working with brake lines, take care not to damage the plastic coating. Brake lines are normally supplied without end fittings. When replacing lines, pay attention to the thread diameter of the connection. Install the fitting onto the tube and flare the end of the tube. Observe the design of the flared end.

When bending a tube, use the old tube as a template.

PROCEDURE

1. Raise the vehicle and support it on stands.
2. Lightly depress the brake pedal and hold it. To do this, place a wooden block between the seat and the pedal, moving the seat forward and back as needed. This prevents fluid from leaking out of the reservoir and air from entering the system after the line is disconnected.
3. Unscrew the union nut and disconnect the brake line.
4. If necessary, plug the connection toward the brake master cylinder.
5. Route the new brake line along the path of the old one. Tighten the M12 union nut to 15 N·m and the M10 union nut to 20 N·m.

* Do not route brake lines between electrical wires. This may cause chafing and failure of either the brake line or the electrical wire. Maintain a distance of at least 25 mm between brake lines and electrical wires.

6. Bleed air from the hydraulic system. Refer to the Brake System Bleeding section.
Caution, check the following:
a) Are the brake hoses secured?
b) Is the brake hose secured in its bracket?
c) Is the bleeder screw tightened?
d) Is there sufficient brake fluid in the reservoir?
e) With the engine running, check the system for leaks. To do this, press the brake pedal with a force of 200 - 300 N (20 - 30 kgf) and hold it for 10 s. The force on the brake pedal must not decrease.
f) Check all connections for leaks.

*Brake fluid must be disposed of in accordance with special requirements.