I ordered a set of new brake lines and received them in the mail today. I was surprised at how short they seem. The front is about 29", which after browsing some posts seems to be ok. But the rear is only 20" or so. It seems like I can still run it, it just won't have the loop as shown in the microfiche, will that be ok when adjusting the chain and what-not? Also, there seems to be a second hose that runs up to the reservoir... is that like the same material as the stock brakeline and do you think I should replace that as well? Are there stainless options for that line or is that overkill?
Sorry, I'd look at it myself, but I'm nowhere near my bike as the garage is a neighborhood over (a Brooklyn neighborhood). I thought I could go seek the hose out before I head over there this weekend.
Reservoir to master cylinder is fine as it is. There is no pressure and there is no SS line for that. Leave the res. to MC line as it is.
I, too, have seen that some companies make a rear brake line that short. I have no idea why. It is not like that in any Suzuki information. Even an old 1989 had the loop. You would have to run it without the loop. It should be OK.
What brand is the cable?
I bought them through L Seven, they're called ABB brake lines:
http://www.lsevenparts.com/products/Brake-Lines-Suzuki-GS500-EK-%252d-ER-1989%252d1994.html
which appears to be the same as All Bike Brakes:
http://www.allbikebrakes.com/products/A.B.B-Stainless-Brake-Lines-Suzuki-GS500-EK-%252d-ER-1989%252d1994.html
Should not be a problem. I bought some Goodridge lines and they did the same thing for older models - shorter.
I still have no idea why because any I have seen always have the loop in front - even 1989's and 1992's. maybe they were different in Europe (oohhh - I can look it up in my German parts catalogues!)
maybe someone else knows something about the reason companies think the brake line is shorter on older GS500's. The same longer line is for all bikes I have seen in the USA. The extra length allows for easier movement of the swing arm and (as you guessed it) tightening of the chain.