Rust zone issue on lower end of hydraulic clutch hose

[duegi]

In the midst of replacing clutch on an '04 R1150R, if you've gotten into the bottom of the motor you know the time involved in working through the layers of parts to get to said clutch.

The protective sheathing/cover on the hydraulic clutch hose is the problem by holding water and not drying out down on the clutch slave cylinder end of the hose. Water gets into the sheathing/cover up by the forks and seeps down and sits on the lower hose connecting point to the banjo fitting which connects to the slave cylinder. I live in Iowa City and stored the moto last November '14, when removing the slave cylinder (April 8, 2015) in the midst of my clutch replacement I had water draining out of the clutch hose cover. In short the water promoted rust and ruined the connecting point of the hose to the fitting. When considering the lack of drainage and not having a chance to dry out I wonder how long the bottom connector had been rusting as 2/3 of the connector crimped portion was rusted away.

If you have access or are working on the low end try to trim the clutch hose sheathing/cover up a couple of inches from the slave cylinder so water can drain out. Or if replacing clutch hose or any other reason you may be in the lower end of the moto trim the hose up and figure out a way to keep the sheathing/cover from sliding down and promoting rusting of the fitting connector. Perhaps just trim the sheathing off except for contact and tie/mount points to the moto as water won't bother the hose but of course just rusts metal.

The main thing is make sure water can drain out the bottom of the hose/cover and allow the lower connection to dry out.

[peels]

Iowa city, hey? maybe Ill see ya riding around.

Ill be up there this weekend to check out the BMW shop's new ownership grand opening.

thanks for the heads up on this!

[sykospain]

Yep, this is what he means:-

http://s864.photobucket.com/user/sykosp ... ort=3&o=14

AL in s.e. Spain,
where the rain falls mainly - more often than it ever did -, mainly because Communist China is commissioning one new coal-fired power station EVERY WEEK and poisoning the planet far faster than you or I do whenever we spray underarm deodorant...

[duegi]

Another good reason to trim back the sheathing is the hydraulic clutch line is $184.00 USD. Very pricey because of the a-typical 6mm banjo connector on the slave cylinder end of things. Usual size is 10mm which would mean after market for $50...

Seriously take some time and dig around the bottom end of the clutch hydraulic works and see what's going on down there. Especially if you are in a wet or rainy area as the lower end may have never dried out.

[AZBMWRIDER]

After seeing the price quoted for a clutch hydraulic line, thought I'd post this .

http://spieglerusa.com/brake-line-kit-174.htm

I've got three bikes with brake lines from this company .
I would reccomend their products without hesitation .

[peels]

I had forgot to mention....That area on mine was not too bad when I had my slave out. A little white mineral buildup. No rusty corrosion yet. I scrubbed it with scotchbrite and oil. I didn't trim that back though...

[duegi]

AZ BMW
The top of the hydraulic line is a standard 10mm 90 degree banjo connector, it's the blasted bottom one that was the problem as it's a 6mm 90 degree banjo connector. I was looking over the link you shared and couldn't find anything about a 6mm banjo connector. Though maybe they do something custom? Probably still come in way lower than the $185 for the oem BMW part.

[AZBMWRIDER]

Call, or email them, they will be able to answer the question quickly .

[JayTee]

Hi,

I changed my clutch cable 1.5 years ago, bought separate parts from Venhill in UK:

This is the special 6mm banjo:
Product Name: 3-60163C M6 90DEG LONG SIDE BEND BANJO CHROME
Line Total: £6.30

I ordered 1175mm long line, but I think 1200mm would not be too long. 1150mm would have been too short.
Product Name: 3H1175 1175mm Braided Stainless Steel Line with Teflon Tube
Price: £19.33

I am not sure which banjo I used for the master cylider end, maybe the one with 75 degrees bend:
Product Name: 3/60087S M10 45DEG BANJO STAINLESS STEEL
Price: £7.52
Product Name: 3/60086S M10 75DEG BANJO STAINLESS STEEL
Price: £7.52

Assembling the line is very easy, and the quality of the parts is really nice. I used a drop of strong thread lock for the line/banjo connection to give a piece of mind. I am using Venhill lines also in the front brakes.

They seem to have a distributor in USA too: http://www.venhillusa.com/

-JayTee