Failed WOF - Non crimped kevlar brake hoses

**Hoon** · 18th January 2013, 09:25

I'm just putting my ex-race bike 91' ZXR400 back on the road. Took it in for a WOF this morning and got failed due to my front kevlar brake lines having a screw on hose connector when they are required to be crimped on.

Other than sourcing original parts and replacing, are there any other options available?

**Akzle** · 18th January 2013, 09:34

Originally Posted by Hoon

I'm just putting my ex-race bike 91' ZXR400 back on the road. Took it in for a WOF this morning and got failed due to my front kevlar brake lines having a banjo connector when they are required to be crimped on.

Other than sourcing original parts and replacing, are there any other options available?

crimp them on.?

(i thought banjo bolts were perfectly fine... is your WOF guy an a55hole?)

**Madness** · 18th January 2013, 10:09

1. Read this thread -> http://www.kiwibiker.co.nz/forums/sh...hlight=crimped

2. Familiarise yourself with the search function

3. Have a nice day & come again.

**Hoon** · 18th January 2013, 10:14

Already done and read that thread smartass. I'm asking for options, not questioning legality.

**Hoon** · 18th January 2013, 10:24

Originally Posted by Akzle

crimp them on.?

(i thought banjo bolts were perfectly fine... is your WOF guy an a55hole?)

Sorry my bad. I meant to say it had an illegal screw on fitting at the end of the hose, not banjo connector. Edited original post.

**Madness** · 18th January 2013, 10:33

Originally Posted by Hoon

Already done and read that thread smartass. I'm asking for options, not questioning legality.

Perhaps you could have made your O.P a little clearer then, smartarse. Good luck, fucked if I'm going to help you.

**Murray** · 18th January 2013, 10:44

My mate just took his wee 250 to a VTNZ and got failed for being to noisy although the mechanic working on it said absolutely not. Also failed due to indicators flashing too slow when the motor wasnt running!!!

Law unto ther own!!

**bogan** · 18th January 2013, 10:48

Originally Posted by Hoon

Other than sourcing original parts and replacing, are there any other options available?

Get some aftermarket ones with crimped ends, or it might be possible to get some crimp ends put onto your existing lines? Would depend on what end termination you have, and maybe whether there is a little extra free length. I think there are places in NZ that do custom length ones, not sure who though.

**Hoon** · 18th January 2013, 11:43

Yeah it's either replace/fix the offending section (where it connects to the master cylinder) or replace the whole lot.

Looking on trademe this looks to be my cheapest solution so far at $40. Guess the kevlar hoses will just have to go into the spare parts box awaiting my return to world F3 domination (cough!).

Originally Posted by Madness

Perhaps you could have made your O.P a little clearer then, smartarse. Good luck, fucked if I'm going to help you.

Sorry after rereading my original wrongly worded post I can now see how your response was justified and helpful. My apologies.

**bogan** · 18th January 2013, 11:47

Depends on the budget, but I wouldn't under-rate kevlar (I assume they are similar in operations to stainless braided lines) lines for road use, might be worth spending a bit more to keep the same braking feel.

**jim.cox** · 18th January 2013, 11:54

Originally Posted by Hoon

. Guess the kevlar hoses will just have to go into the spare parts box awaiting my return from the WoF testing station

There, fixed that for you

**Skiwi** · 18th January 2013, 11:56

I got knocked back at the last WOF for the same thing, paid the $300 and installed the stainless braided lines, made no difference to to the feel of the bike, just my wallet

**imdying** · 18th January 2013, 12:05

Post a clear macro photo of the end of the hose and I'll tell you if it's legit or not.

Screw in banjos are not illegal so long as they're screwing into a female that is crimped to the hose. End of story. Anybody that tells you anything different needs to be re-educated.

**Hoon** · 18th January 2013, 13:33

Ahh ok. After a closer look mine seems to be crimped under the black heatshrink?

Click image for larger version.

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**imdying** · 18th January 2013, 14:07

That appears to be fine. If you remove the banjo, you should not be able to remove that female end.

It's perfectly legitimate to screw in a banjo fitting like that.

Tell the goober to look in the VIRM, section 8-1, item 18, part g, and note 2.

g) has an end fitting that is not attached to the hose by means of swaging, machine crimping or a similar process (Note 2).

So long as that female end cannot be removed (and given it has no double nut to undo, that certainly appears to be the case), it's legitimate. Screwing things on the end (like banjo adaptors) is fine, even the OEM do it at times (have a look at an R32 Skyline for example, the hose stops at the strut, and then a steel pipe goes from there to the caliper, same as a Mk1/2 Ford Escort).

You can view it here:
http://vehicleinspection.nzta.govt.n...-parking-brake

What that rule is designed to get rid of is race fittings that use a ferrule/olive to retain the end piece. That is squished on to the hose by tightening two nuts together, and is then unsuitable for reassembly without shortening the hose and replacing the ferrule. Even those are ok after initial assembly, but people unfamiliar with brake hoses have been known to undo that fitting instead of unscrewing the adaptor out of the caliper.

These are examples of unsuitable for road use fittings:

Note in the last picture the 'two nuts' that allow disassembly; these do not feature on your hose.