Hose problem - Hayes Nine's

[Rascal]

I had bought a set of these at one of the Jenson sales, (despite me knowing better), to use for a spare bike I was going to build.

I had to cut the length of the hose so I removed it from the lever housing and cut it cleanly with a surgical blade. For reassembly I put in a new compression bushing, bled the system and all was good in the world - until I actually used the bike.

When grabbing a good handful of brake, the hose popped out of the lever body.

I tried it again with a new bushing and same result. Hoping that the third time was the charm, I cut off more of the hose, new bushing, rinse and repeat - and the hose still pops out. WTF??

Has anyone else had this problem?

[Rockinthecasbah]

did you use the square bushing or the one with the hump in the middle this === or =<>=, either way it must be too small or it wouldnt be able to pop through just get another bushing the hayes nines are great i have them on two bikes, i ust cut the one on my 4x hopefully it wont have any problems

[Rascal]

I believe I used the bushing with hump. I guess I wasn't really clear in my original post, the bushing doesn't pop out of the body, the hose pops off the bushing.

I wonder if your logic applies anyway, maybe the small tube that goes inside of the hose is too small. It seemed to fit snugly, but it definitely wasn't a pain to push into the hose.

[2wheel_lee]

Sorry to hear that you had to go through all that, but it's really a simple problem.

I'll assume you used the right parts, but I'd bet that you didn't get the nut tight enough. Look at how far the other nut is threaded into place. From what I remember, there is no torque spec, and you have to crank that nut tighter than one would normally think.