Santa Scored! New brake lines! - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 6 Old 12-26-2009, 11:49 PM Thread Starter
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Santa Scored! New brake lines!

Santa, or rather my vintage '70's dirt bike nut brother, got me Russell (Eldelbrock) stainless braided brake lines for my A16! I have one question about the torque specs for the banjo bolts. The instructions merely mention not to over torque them....? (with new crush washers of course).

So, does anyone have any ideas on the ft/lbs of torque? I didn't see anything in the owners manual as I suspected would be the case. I know, I should get a Clymer manual, but I have no idea if they mention torque specs for the brake lines. I would imagine it would be something pretty standard for most bikes.

SK
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post #2 of 6 Old 12-27-2009, 09:00 AM
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I don't have the torque spec on the banjo bolts. I snugged them down with common sense and never had an issue.

You'll LOVE the front brake feel with the new lines.. Huge improvement.. Rear, not so much.. The back's not very long to begin with and it really doesn't change it much, or at least that's what a few of us who've changed them have found.

The only hassle is getting the brake lines back full of fluid and getting a clean bleed out of them.. Have plenty of NEW brake fluid on hand when you start the project. I think we've switched all our bikes over to Valvoling Synthetic Brake Fluid.


Not that much more money than regular stuff and available pretty much anywhere.. I think I typically buy it at my local Advanced Auto Parts.

Looking forward to what you think about the new lines!!!
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post #3 of 6 Old 12-27-2009, 01:11 PM Thread Starter
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OK, well I don't think I can get Valvoline synthetic today, and what's up with DOT3 & DOT4 ? I guess I don't have a clue as to what the DOT thing means(but that's why I'm here), except that the higher the number the more expensive it is...exponentially! I just replaced all the fluids in the bike after I bought it, and used NAPA DOT4 brake fluid. The old stuff was the color of maple syrup.
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post #4 of 6 Old 12-27-2009, 11:41 PM
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If I'm not mistaken, it's got more to do with heat resistance.. And the 3 and 4 designation means the fluid can be used in either a 3 or 4 system.
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post #5 of 6 Old 03-31-2010, 02:18 PM
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anyone have a suggestion as to where to get a brake line kit? i've heard complaints about ordering from KLR650.com. anyone have experience with them? or the kit they sell?



thanks for the insight.

This is the first time I have messed with brakes. what is involved in 'bleeding' brake lines? do I keep filling the reservoir and pumping the brakes untill the bubbles stop? I've got a clymer manual on the way from amazon. should provide some ideas.
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post #6 of 6 Old 03-31-2010, 06:04 PM Thread Starter
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My brother(Santa) got mine at a local shop. These were the "Russel" brand made by Edelbrock. My only problem was with the mid line clamp at the left fork. It was malformed and I had to bend it a little to get everything to fit nicely. Other than that, it was a simple chore. Bleeding the brakes are another matter, and your Clymer manual will give the necessary instructions, but I believe that you should get experienced help if you can, or at least watch someone do it. I learned on cars 40 years ago when I was a gopher in an auto repair shop.

I just did a 130 miles on back roads in the Oregon coast range one dry day, and the brakes are way better than the stock setup... which is a good thing since my buddy tends to slam on 'em for no apparent reason sometimes. I think he just likes to see the gravel fly.
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