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Brake hose information
Brake Maintenance
Technical information

Brake hose install - Moto


Brake fluid is toxic, avoid contact with eyes and skin. Do not ingest.
Most motorcycles use DOT 3 or 4 Brake fluids, which may be mixed. DOT 5.1 can also be mixed with DOT 3 & 4.

DOT 5 is silicone based and not compatible with DOT 3, 4 or 5.1, do not mix.
Most types of brake fluid harm automotive paint and plastics on contact, take care when using this fluid: any spills MUST be immediately cleaned up.
Dot 3, 4 & 5.1 brake fluids are water soluble and may be rinsed offwith water.  DOT 5 is not water soluble.


Thank you for purchasing STAR PERFORMANCE brake hoses, for the best fitment onto your vehicle, safety, and to get the optimal performance from this brake kit, read completely and follow carefully instructions below:
  • Check that package contains all the hardware you require.

    Package contains hoses, supports ( if required ), washers and bolts for your motorcycle.
    A double bolt would be required for full length front brake kit on a twin front disc motorcycle.
    *Note bolt thread sizes on bolts supplied if motorcycle has aftermarket parts.


  • Compare hoses from this kit to your vehicle’s, make sure they fit before attempting to install this kit.
    On modified vehicles, note that you have the correct matching hardware before you start. If not, stop right away & contact us or your dealer.
  • Prior to removal of original brake hose, note the original routing and placement of clamps if any.
    Note orientation of banjo ends and hose. Denote with paint marker if necessary. This is especially crucial for short ABS link hoses & motor car fitments.
    Arrange hoses and compare new STAR Performance hoses to old hoses on motorcycle. Confirm hose lengths and fitment.
    Orientate and ensure which hose end go where.
    Check all is well before starting on removing anything. When installing this brake kit, follow the original routing unless otherwise specified in this kit’s instructions.


  • Remove supports if any and check that hoses are free. Place some absorbent paper towels around the reservoir to soak up any spillage. Protect paintwork and plastics ( especially speedometers ) from brake fluid.


  • Bleed brake system dry, and remove old hoses. Have some rags and water ready in case of drippage or spillage. Water neutralises brake fluid.
    In the even of drippage or spillage, immediately soak up brake fluid with paper towel then wipe off residue with wet rag.
    There is a rubber sealing diaphragm under reservoir cover. Take care while removing to prevent spillage or drippage onto motorcycle. 
    Discard old copper crush washers. Never reuse these.If brake hose removal is tedious or complicated, to avoid brake fluid drips, bleed  hoses, remove from caliper & pump, wrap hose ends in plastic bags and tape bags shut and continue with hose removal from motorcycle.

    *If sediments are present in reservoir, to prevent introducing more sediment into caliper body, drain reservoir with vacuum tool and clean reservoir before continuing with to bleed dry system.


  • Clean sealing surfaces on pumps and calipers. If replacing bleed nipples, check threaded hole after old bleed nipple is removed for any debris or loosened sealant. Remove if any.

  • Install new STAR Performance hoses. Align hose ends as required. If hose ends require adjustment, slide down strain relief and rotate collar of hose joint to desired angle then reinstall strain relief. If strain relief is tough to slide down hose, gently squeeze either end of strain relief to form lip, introduce light lubricating oil and try again. Carefully.

    The end fittings on these brake hoses are correctly aligned, if there’s a need for realignment, slide rubber grommet on hose end away from fitting, use a plier and rotate the hose to desired angle. Do not grip other part of hose!
    If the brake hose you are installing uses screw in fittings, it should be installed loosely, aligned properly, then tightened fully. If theirs is a need to realign hose, fitting must be loosened slightly. Always install banjo end of hose first.
    There is no need to use PTFE tape on any fitting, if used improperly these may end up as debris in the brake system. Loctite 242 or Loctite 542 may be used for security purposes.


  • Ensure correct banjo / fitting alignment while tightening and maintain proper torque on bolts ( 23 Nm ), bleed nipples ( 6 Nm ). Tighten banjo bolts to required specifications for your vehicle.

    *Do not over tighten banjo bolts.
    Note: Damage to screw threads on caliper or master cylinder may occur!.
    *Do not over tighten screw in connections.
    Note: Damage to screw in connectors may occur!


  • Reinstall supports if any. Move motorcycle steering from lock to lock and ensure that hose is free of contact from any part of the motorcycle while in motion. If hose contacts or rubs against part or bodywork, adjust hose routing or mounting until hose is free of interference.

    Check that the hoses are not trapped, stretched tight, kinked or twisted by steering or suspension movements.


  • Brake hoses must not be twisted or coiled when installed, this could impair brake performance and hose life. Minimum bend radius is 20mm.

    Check that the brake hose do not come into contact with engine, exhaust, or live electrical terminals.

    Check that brake hoses do not chafe against bodywork, paintwork or other surfaces. If necessary, use hose clamps to route hose properly. 


  • Fill brake system with fresh brake fluid.
    Before filling master cylinders, pay attention to the state of your brake pads. If these are half or worn down, you may want to fill it to the middle of the cylinder. If the brake pads are new, you may want to fill it to the upper limit line. Note that an overfilled master cylinder will cause difficulties in pad changes if this is overlooked. And when the brake system heats up and fluid expansion takes place,  there is a possibility of brake fade or drag occurring.

    When pouring in brake fluid, avoid splashing or pouring from a height to reduce formation of air bubbles. Brake fluid is viscous, bubbles formed will take time to dissipate and prlong your work time.
    Bleed brake system, when bleeding, press down on bleed hose or bleed nipple to lessen possibility of air getting pass the bleed nipple threads. Check that master cylinder returns to starting position after every stroke.
    Particularly on the rear brake. This is because the rear brake is usually less used and the tendency to be overlooked. Most of the time we find a lot of pump kit failures on the rear brake pump.

    A sign that this has happened is the presence of brown rust colored brake fluid when you bleed the brake system.

    If rearsets are modified, do ensure that rear pump operation is smooth and consistent. If pump plunger is offset, pump body will be damaged over time.

    Brake fluid is a little viscous and as such, air bubbles will travel slowly through the system, especially if it is a long hose or an ABS system. Allow time forair bubbles in brake fluid to settle and travel to the bleed points. 
    To achieve optimal performance, after first bleeding cycle, tap on hoses and wait 10 minutes to perform final bleeding. May just be 2 cycles at every point.
    This makes all the difference.

  • If performing manual bleeding, avoid applying fast pressure to pump. Air in the system will cavitate, air bubbles will collapse into much smaller bubbles. This will slow you down. Apply deliberate and consistent pressure to pump while bleeding. Use firm, full strokes and ensure lever returns fully on every stroke. Use caution bleeding brake system. Bleeding tubes tend to whip off and fling off brake fluid. Be patient, deliberate and careful.

    Check brake operation, brake lever should feel firm after bleeding. To check apply firm pressure on lever for 30 seconds, lever should maintain it's depressed position, if lever depresses further, check for leakage or pump seal failure. Check thoroughly.

    Clean motorcycle. Wash off and dry motorcycle. Use paper towel to dry off, soak up and trace of moisture on all connection points completely. We recommend that you dry
    inside of bleed nipple bores as well. Twist paper towel into small ends for this. Use care, avoid leaving debris in bleed nipple. Fluid buildup in bleed nipple will cause buildup of debris, possibly blocking nipple. Uncovered bleed nipple collects road
    grime, dirt and moisture. Cover bleed nipple with cap when dry. Recheck motorcycle and ensure all is well. 

All ok? Time to ride.