2002 Rear MC Brake Line - BMW Luxury Touring Community
 
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post #1 of 4 Old Sep 15th, 2013, 8:25 am Thread Starter
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2002 Rear MC Brake Line

I am replacing the brake lines on my 2002 (w/integral and BMW calipers) and am having a problem. The line running from the MC behind the foot rest burst. I have various sets of instructions but none of them address how to remove the top banjo bolt of this line.

The bolt is so close to the frame I cannot see how I will ever get an Allen in there and remove it. What has worked for any of you?

Thanks in advance!

Peter Tessin
2002 Champagne
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post #2 of 4 Old Sep 15th, 2013, 3:38 pm
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Re: 2002 Rear MC Brake Line

I just changed all the brake lines on my 2002. I took the master cylinder off the foot rest plate to get the banjo bolt out. I have two brake lines running to the rear master cylinder, the original line for the bike, & one for the sidecar brake. It was fun trying to get it all back together so they would all line up

...Then when it was all good, & I was put the master cylinder on for the last time. I pulled the threads out of the foot rest plate... Hele coil time

Patric Blackman
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post #3 of 4 Old Sep 15th, 2013, 4:40 pm
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Re: 2002 Rear MC Brake Line

It looks tight but the manual says to remove a retaining plate. Not sure if this helps or not. Pay close attention to the routing of the the pressure line and the supply line from the reservoir. They are twisted a certain way.
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post #4 of 4 Old Sep 15th, 2013, 9:20 pm
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Re: 2002 Rear MC Brake Line

Quote:
Originally Posted by Ranger
I am replacing the brake lines on my 2002 (w/integral and BMW calipers) and am having a problem. The line running from the MC behind the foot rest burst. I have various sets of instructions but none of them address how to remove the top banjo bolt of this line.

The bolt is so close to the frame I cannot see how I will ever get an Allen in there and remove it. What has worked for any of you?

Thanks in advance!
Peter,

I just went through this on my 2002 a couple of months ago. First, remove the battery. That will give you access to the bracket/connector between the hose and metal line. A 15mm (I think) wrench will fit on the bracket to keep it from twisting when you use an Allen wrench on the banjo bolt. Yes, the fit for the Allen wrench is tight, but it will go. I think I put the Allen wrench in the head of th bolt and then levered against the frame piece that is in the way to get the Allen wrench in straight. If the bolt is as tight as mine was, you will have to clip some vice-grips on the Allen wrench to get sufficient leverage to break the bolt loose. You must keep a tight grip on the 15mm wrench to keep the bracket from bending.

A tip. Once you get the connection apart, tie a 2 or 3 foot long piece of string to the upper banjo fitting. Then, tie the loose end of the string to the shock or something else near the bracket. After drawing the hose out by the footrest end you will be able to use that string to tie onto the new brake hose and pull it up through the exact path of the old hose.

Ken
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