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Gen 3 stainless steel brake lines

16K views 58 replies 17 participants last post by  Reddevil504  
#1 · (Edited)
So I did it, finally. I ordered a front and rear set of SS brake lines from klr650.com. Advertised as Edelbrock but showed up labeled Russell with a Edelbrock name on the back of the package. The front fit perfectly and I filled it with Motul 600. Bled it out , all good.
The rear line they sent me is too short and will not work on a gen 3. I asked when I ordered and they stated it would work but nope. 2" too short. The gen 3 swingarm is 2" longer, go figure. I reached out to them to start a return. I'll need to wait for Galfer to bring one to market. I believe they are finalizing it now. It's 100 degrees here so I'll test the front brakes tomorrow and follow up. I already lost 5lbs in sweat so I'm done for the night.
 
#5 · (Edited)
I tried to use the Edelbrock rears installed exactly how yours in the picture but they are at least 1 1/2" short. I'll take a rear line now if you know where? Gen 3 non abs model. It appears Galfer has them ready to go on their site but it won't move to the shopping cart. Galfer, take my money, please! 😉
The front fit good.
 

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#7 ·
NICE!

Notice the clamp at the rear caliper mounting point: It's part of the kit and makes the line fit PERFECT!

The lines in the pics are the prototypes. The lines you get might be lightly longer/different...but...if there's ANY changes? It was only to make them fit even better!

I think they used Motul DOT 5 fluid...? All I know is the brakes fell WAY better and the rear is identical to the rear on my CRF-RL/Xs.

They ARE making rotors...including a HUGE front!
 
#8 · (Edited)
I called the Galfer tech number and they said the rear line is 30". The Russell is 25" so 30 should work good. Says 2 day shipping but I'm heading out of town Friday afternoon for 10 days with the bike soooo. If they arrive before 4pm Friday, I'll take it with and install it while I'm up north. Thanks for the heads up on this.
I plan to use Motul 600 DOT 4.
 

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#9 ·
The Galfer lines are made to order so it won't be here for a week or so. No biggie. I'm sure they will be producing a bunch to sell wholesale soon. I wanted to mention it incase anyone else orders them now expecting it to ship same day.
 
#12 ·
I was about to ask how one installs a Rear brake hose on the front of a KLR as I viewed all of your pics in the series. ;)

The rear hose has yet to be installed. :)
 
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#13 ·
Good catch. I edited the thread title. Funny thing is, Kelly from klr650.com reached out and asked me to send him pictures of the rear brake line packaging. Best guess is they are looking to stock the Galfer lines. Idk.
 
#14 · (Edited)
I had a bit of a scare today when I lost my rear brake after about 20 miles of mountain gravel roads. I rarely even use the rear on the street, but I was dragging tail around almost every corner and there were some fairly long, loose downhill runs. Fortunately I was nearly out of the woods when I noticed the problem, and once it cooled down on the street the pedal came back.

I had ordered a set of the stainless Galfers already and the box came while I was out riding today, so I just finished getting them installed. The rotor didn’t look discolored and I didn’t pull the pads, will see how it feels tomorrow.

I had a pretty epic ride today down Horse Pasture Road in Lake Jocassee South Carolina and then went up and down Pinnacle Mountain in North Carolina on my way home. I even saw a big black bear run across the road, as well as a wild turkey and a deer standing right by the road.
 
#15 ·
I would suggest using a good quality brake fluid with a higher boiling point. I like motul 600. Just don't skimp on the fluid and make sure it's a new unopened bottle. I smoked my rear brake on my first real off road ride. The powder coating burned off the rear caliper. That was before I put the better fluid in. It's much better now.
 
#22 ·
Well bummer. The Galfer line they sent me won't work. 50 bucks wasted, again. I may see if there is a custom shop around who can cut the line down and crimp on a banjo connector. Not much else to do at this point.
 
#24 ·
I spoke with galfer and they told me the brake line they list for the gen 3 is the correct size but I can confirm it's too long. I called a 2nd time and they told me I had to route the line the same way as oem and I told them nope.
I sure hope someone can develope and sell a line that goes forward to eliminate the aircraft carrier tail hook design.
 
#27 ·
The gen 3 swingarm is 2" longer, go figure.
Related but slightly off-topic: does this mean that the Gen 3 has a different wheelbase than Gen 2?
 
#31 ·
Has anyone found a brake line that works?
Was going to order the Galfer lines. I talked with them and they said
Front Lines FK003D1004-1
Rear Lines FK003D1004R
The front fits the gen 3 and I confirmed it personally. The rear they sell is about 2" too long to route it forward off the caliper the way I want to. If you follow the factory route and put the big goofy loop off the caliper, the galfer rear fits. I thought about taking the rear to a local shop and have them shorten it.
 
#33 · (Edited)
The stock Galfer KLR line is about 4" too long IMO, so it loops up above the handlebars, which makes bleeding the recalcitrant front brake even more annoying. I have 2 of them. If I order another one, I'll order a custom line that's shorter.

EDIT: That's for the Gen1 and Gen2. Dnn't know about the Get 3 as it is a different line.