How To : Replacing A Brake Hose & Eliminating ABS

[90GTVert]

Replacing The Front Brake Hose And Removing A.B.S.

I need a new front brake hose so I headed out a bit ago and checked out the situation with the ABS while removbing my leaking front hose.

I started by removing these 6 phillips screws that hold the front fairing in place.


Then I removed the lower screw in each side, seen here. (Bikes that haven't been wrecked may have more screws/parts.)


Now I remove this allen head bolt. It is the last fastener holding the front on and there are wires attached, so hang on to it.


The headlight harness must be disconnected, and then the front fairing can be completely removed.


Now I place a catch pan under it and remove this bolt holding the brake line to the ABS box, being careful not to lose any washers.




Then I remove the adapter holding the ABS unit onto the brake caliper, as usual make sure no parts get lost.




Now I pop the brake hose out of any clips holding it to the scoot.


Next I remove the 6 phillips screws (4 front, 2 rear) holding the gauge panel on and set it out of the way, being sure no cables or wires are being pulled.






Next I put a paper towel or two under it and remove this bolt holding the hose, again making sure not to lose any washers.




I put the bolt back in after I pull the brake hose out, so I won't lose anything and it keeps stuff out of the master cylinder.


That does it for removing the brake hose. Now, back to the ABS removal...

The bolt going into the ABS box is smaller than the caliper needs, so a new bolt is needed. You can't just run down to your local hardware store and grab a larger bolt though. You need a bolt for this application, with passages in it. It is actually the same as the bolt in the upper hose. I need to order a brake hose anyway, so I'm just going to order another bolt like the one going to the master cylinder and the 2 rubber and 2 metal washers it uses as well.

Here is the ABS box adapter compared to the bolt going into the ABS box.




Here is the bolt from the master cylinder end to show you the passages.




Here is the bolt going through the hose in the bottom and the one in the top.


Here are the part numbers from www.vento.com 's parts section that I am using to remove the ABS box from my Triton...

- 1 - Bolt - Code 45037J00P000 - ID 1895 - $0.78
- 2 - Washer - Code 45029J00P000 - ID 1886 - $1.04

I got my brake hose and parts for the ABS box removal in a couple of days ago and installed those.

I started by routing the brake hose through the lower part of the instrument fairing.


Then I put the bolt and washers through the cable, and secured it to the master cylinder with a 12mm wrench.




Next, I pushed the rubber piece on the hose assembly into the holder on the steering stem. (Some scooters have more than one of these.)


Now I used these new parts to attach the hose to the caliper, just like I attached the hose to the master cylinder. It's just that easy to remove the ABS.






Now you just need to bleed the brakes.