Brembo Rear Hand Brake Issue - Hose Hitting the Handlebars

[TokyoMX]

Hi. I have Brembo Rear Hand Brake replaced from Formula. The brake hose is hitting the handlebars, and I cannot adjust my lever to the position I want to.





I contacted CS at Stark but they say my "aftermarket" Pro-Taper is the cause of the problem. I think they are saying my bars are too fat. WTH?!

Right (Front) side is ok. The hose is bent to clear the bar, but barely.


Anybody here have the issue with this? Stark say I do have a correct hose, but clearly it's not working. I don't want to try bending it myself, cause more problems.

Thanks.

 

[Philip]

Flip the upper banjo. You'd have to twist the hose, it can take a 180-degree twist. Not optimal but better than other alternatives.

 

[TokyoMX]

Flip the upper banjo. You'd have to twist the hose, it can take a 180-degree twist. Not optimal but better than other alternatives.

Thanks for your response, but how is flipping straight banjo will solve the problem? Please educate.

I need to take it apart to see if it's REALLY straight, but they are as far as I remember.

By the way, did you have the same issue?

Thanks.

 

[Philip]

Oh! Sorry, I thought I saw a slight bend in the photo.

You can usually bend these lines too. I have done it in the past. Use some soft aluminum on both sides of the banjo when clamping it a vice.

I used an Amazon brake line, and it had a bend, but it was in the wrong direction. I tried to unbend it, but then flipped it 180 degrees instead, and it worked.

 

[svtride]

I had a similar issue with my 300’s Brembo front brake master cylinder when I couldn’t get the brake lever where I wanted it…I simply cut off the tab on the MC casting and that allowed me to rotate banjo fitting more vertical to re-route brake line. I never could understand/figure out the rationale why Brembo placed that tab there anyway..

 

[AL_V]

I think the tab is to keep the banjo from rotating when you tighten the banjo bolt.

 

[TokyoMX]

Oh! Sorry, I thought I saw a slight bend in the photo.

You can usually bend these lines too. I have done it in the past. Use some soft aluminum on both sides of the banjo when clamping it a vice.

I used an Amazon brake line, and it had a bend, but it was in the wrong direction. I tried to unbend it, but then flipped it 180 degrees instead, and it worked.

That's good to know. I'll try bending it out a little bit to clear the bar, watch for not scratching the banjo.

Arigato.

 

[TokyoMX]

I had a similar issue with my 300’s Brembo front brake master cylinder when I couldn’t get the brake lever where I wanted it…I simply cut off the tab on the MC casting and that allowed me to rotate banjo fitting more vertical to re-route brake line. I never could understand/figure out the rationale why Brembo placed that tab there anyway..

View attachment 13682

So this problem is a Brembo thing, then? Stark is my first non-Japanese bike in past 25 years or so, that it's a news to me. I would like to keep the tab as its design, but will keep in mind this trick. Thank you.

 

[Varq]

So this problem is a Brembo thing, then? Stark is my first non-Japanese bike in past 25 years or so, that it's a news to me. I would like to keep the tab as its design, but will keep in mind this trick. Thank you.

It does look like the bar bend is the problem. If you are not running shorter levers you could try that. Doing so would allow you to move the brake master cylinders more towards the end of the bars and away from the bend in the bars that is causing the interference.

 

[TokyoMX]

It does look like the bar bend is the problem. If you are not running shorter levers you could try that. Doing so would allow you to move the brake master cylinders more towards the end of the bars and away from the bend in the bars that is causing the interference.

Thanks.

I don't know, my bar is SX Race Bend from Pro-Taper, which is a very basic like stock Yamaha bars. I also have ASV Short levers on left and right, that works great. Just that Left side Rear Brake sits too high compare to right. I will check to see if moving it outward helps with this problem.