You're right, I wouldn't miss my back brake all that much.

There must be a bit of thin metal pipe about that you can use as a bodge. Diesel injector pipe maybe, car brake line, etc. You only need an inch or two. You need to get it inside the existing hose, the further the better. To make it less likely to fire out under pressure, scour some grooves around it with a file or something. If you can't find any hose-clips, fence wire should do the trick quite well. Use a few separate loops, you might get more pressure that way.

You can't patch hydraulic hose. The pressures are too great.

You can live without the back brake. Just ride slower and safer than normal.

Hydraulic hose with that bore isnt uncommon. Brake hoses on bikes are all the same size. It's not just for bikes either.

There has GOT TO be a bike shop, spare parts shop or garage which will have some. Any old hose off any old bike will do the job.

Dont forget to use new copper or aluminium sealing washers. If you cant, heat the old ones up in a hot oven or blowtorch them.

Break Repair
 

Hi Pete and All,
:mchappy:

With the intention and in the spirit of being helpful and innovative not everything has to lok the way you think it should or be as the manufacturer made it.

Repairing things like brake hoses can be a bit of a problem I would think that India would be an innovative place as people make lots of things out of what they have.

I am thinking that there may be some old cars or motorcycle shops around the place specially where they have people movers motorbikes with little passenger carriers either to the side or in front ….or machine shops with equipment like lathes, drills and perhaps it would be helpful to have some oxy acetylene welding equipment. Braising/welding with brass rod should work well, also silver soldering …. Not tin or the one you do with a soldering iron….

Ok the first thing to do is find a short flexible hose that can be placed into the centre of a steel break line … perhaps a piece of break line from a wreck…. The beset place to get a short flex line from is out of an old car at the differential end where the brake line goes from a single steel line and then into a T section allowing the fluid to be directed to the brake cylinders use the fittings if you have to and the steel lines that are in the T section.

On your bike master cylinder there is usually a banjo or circular part that a special bolt fits through … and at the caliper end there should be a similar fitting or the same …… Once you have laid out all the bits and you have
The banjo from the m/cyl and a short piece of steel line with a fitting that will fit to your secondhand hose….just a short flex line will do and then another fitting that will join the flex line to the brake line that will go to the caliper …… last of all you will have the Banjo that fits to the caliper…..
The beset place to get a short flex line from is out of an old car at the differential end where the brake line goes from a single steel line and then into a T section allowing the fluid to be directed to the brake cylinders use the fittings if you have to and the steel lines that are in the T section if other pipe flaring equipment and perhaps parts are not available , so basically once you have all your parts lid out then remove the existing clamps that hold the hose to the banjo….. see what you have to do to attach the pipe to the banjo by welding it to the banjo( it is best that somehow the pipes overlap , use another piece of tube over the top and weld in place > You may have to enlarge the hole in the banjo that the pipe goes into . This can be done by carefully drilling out the old pipe, fill any other holes so they are blocked.

Perhaps this might be better than a repair that can break down.

It is also a good trick if you can cover the steel pipe with some clear plastic tube or similar where it goes to the caliper along the swing arm
This should be an effective repair and perhaps last the rest of your trip.
Look towards being innovative.
Hope this helps

Kind regards
Champ :D

Possibly not, but you can cut out the damaged part and join the pipe back together as I tried to describe. It'll work, my old Suzuki (sj410) ran for many years with a joined (bodged) brake hose.

Yeah, I believe that method was also adopted by Toyota :oops2: