Hi guys

This weekend when I was loading up my KLX the front brake line suddenly burst. Thank goodness it was while loading and not when I was coming up to stop at traffic lights or something like that.

Upon inspection, I found that the way the line is routed on the inside of the forks down near the caliper makes the line prone to rubbing by the brake disc if there is too much slack in the line.

That's what happened with mine anyway - the disc wore a point in the pipe (braided steel line mind you!) and created a weak point which popped when I pulled the lever.

I would strongly advise you check your line is OK so you aren't caught out in a dangerous situation.

 

My braided line is running from the backside of the caliper and up the back of the fork stanchion and leg. I like it back there as it seems less likely to be grabbed by a branch or other trail objects. Are the '09 and later models that much different?

 

yeah post a pic so we can see how not to route it...

 

Too late I'm afraid I've already changed the line, but I had these old photo's:

Original routing:


Routing of my braided steel cable (exact same path as original I thought):


The red arrow shows where the disc rubbed the cable. I can only assume that happened when the plastic fork guard flexed over bumpy terrain.

 

I have a 2009 and the hose is pretty far away. Your green one looks like it needs to be pulled further up through the clamp at the top of the fork guard.

 

Agreed - I did not install it properly. Just thought that it's a simple mistake others might have made and the consequences could be dire.