Fitting HEL lines, problem.

Hi All,

I'd really appreciate some help if anybody's good with brake lines. I've just stripped and cleaned up the calipers on my '99 SV650s (done that before - all finished with no probs) and thought I'd switch the lines for some HEL braided ones at the same time.

I got the kit from brake-lines.co.uk that keeps the front splitter. One line to the rear and a one-into-two for the front. All connected up and looks to fit nicely.

The issues started when I tried to fill the system...

The banjo bolt on the front splitter leaks as soon as you get fluid through it. Not just a little bit and there's no way I can get pressure in the front brake. It's the bolt that's on its own on the left, not the double one that comes down from the master cylinder.

Went back to the HEL instructions (Prat. Read it properly first!) and it said watch the screw threads on Suzukis because some banjo bolts might match the kit and others might not. True enough, the banjo bolts into the splitter are different, with a narrower thread than the ones in the caliper (and the kit).

I've switched back to the original bolts and it still leaks from that joint.

So main question... Have I most likely cross threaded the screw in that splitter and permanently b***ered it up? I've had it back to pieces, switched the washers, tightened it more and it won't stop leaking! Any advice? Is there a sealant that's ok to use on the screws? I read teflon tape somewhere but also advice against it.

Any advice would be great. I'm happy that I know how the thing works and won't go charging off down the road without brakes, but never expected this to be such an awkward job.

iirc some poeple have wrote a email to hel about this and they have sent out replacement bits for free, do a thread search for more clarification
hth

[Sid Squid]

Do not use a sealant of any kind on the brake lines and unions. The copper, (sometimes aluminium), washers are all that is needed.

Just to check: Were the washers replaced, and there are five altogether on the junction as there should be - two on the single connection and three on the double?

Thanks guys, I did have a search but no joy for my problem (other than finding out it's trickier than I expected.)

Yes, brand new copper washers that came with the kit, two on the left, three on the double banjo on the right. Only the left is leaking. So far anyway.

Mainly worried I could have damaged the splitter with the wrong bolt. I'll have it out in daylight hopefully fairly soon and get a better view of the thread.

[Sid Squid]

I think I've got a splitter if you need it.

I don't remember if it's different from Curvy to Pointy, or which one I have. But if it's any use, it's yours.

That could be a lifesaver, thanks! I'll have another crack at it over the next couple of days and see if I can see any damage then might have to give you a shout.

[Sid Squid]

I've just had a think, Pointies don't have a splitter, they have a one piece hose setup with a non removable 'T' piece. Which is a long way round to say 'the one I have must be from a Curvy'.

Whatever, if you need it and if I can find it, it's yours.

Quick note to say thanks for the advice and your splitter offer Sid, but I've cracked it I think.

Took everything apart and went back over all the bits tonight and it turns out that HEL know what they're doing (more than I do? Surely not) and they supply banjo bolts in the kit with different threads - two have narrower threads for the splitter. One is the double length bolt, which you can't get wrong and also a single one.

Put it all back together with new washers and the correct new HEL bolt and it's sealed properly this time.

Long story short, I'm an idiot who should read instructions properly and check the bits in the kit thoroughly!

Just the rear to go now and a final bleed on the front. Back on the road shortly with a bit of luck.