Well I had a little time today so I fitted the rear line. Of course I didn't prepare anything so I had a few problems along the way. You can learn from my mistakes ... or you can just laugh

To start with I bought some brake fluid and a bleed hose, you can see the bleed hose in this pic



Brake line running alongside original



I started by bleeding the old fluid out, a thin open ended spanner would have been a better choice than a fat ring spanner.



I don't think I'd bother next time as it took a lot longer to prime the new fluid when refilling the master cylinder reservoir. And yes I cleaned the master cylinder reservoir before opening it. Be careful unscrewing the lid as the screw heads are made of cheese and they take a little quick twist of the driver to break them loose. Oh yeah that connector in the pic is better of being moved before you start.



Don't do this !!!



I couldn't get my spanner in the space to undo the rear fitting of the hose so I undid this bolt to swivel the calliper up. It worked but you have to not drop the greasy bolt therefore collecting dirt. You also have to re grease it (if you drop it) AND you need to refit the pads into the calliper if you take it off. Oh yeah you have to take the white plastic guard off too.



Ok we take the back of the hose off having rags handy to soak up the brake fluid that leaks out (eventhough I drained it), take the front off and remove the hose being careful not to lose the washer that fall out. Fit the new hose at the rear, leave it loose so you can get the front fitted a bit easier then tighten both banjo bolts to 18ft-lb. Fill the reservoir almost to the top.



Heres where the fun starts unless you have a friend, a 1 man bleed kit or your just very talented. Press down on the brake pedal and hold it,undo the bleed nipple, wait for the fluid / air to escape then nip the bleed nipple up, release the brake pedal.



Repeat until you have clear fluid coming out the hose with no bubbles.



Tighten the bleed nipple to 69 in-lb, that's INCH-pounds not foot-pounds. Pump the lever to fill the slave cylinder and the pads should grip the disk. Top off the reservoir almost to the top and put the lid back on.

Important.

Make sure the brakes are working before starting the engine and there is enough fluid in the reservoir.

If there is anything I missed please feel free to say so, I'm a bit tired and could have forgotten something.

Disclaimer: This is not a guide for you to follow, it is a record of what I did. If you follow what I did and hurt yourself or others I will not be held responsible

 

Great post!

 

Well done garry, good post, how does it work
cheers hatto

 

Dunno yet I finished it on dark and haven't had time to ride the bike yet, it's raining here so I took the car to work today
[8D]

 

G day garry
Any work on the carby yet, I have ordered a pilot from mikunioz, he said they sell the carbs with 45 pilot and 142.5 main so I have a pilot on the way - this is the only place I've been able to source them from
cheers hatto

 

Awesome Mav, pictures look great and really compliment a project like that. Thanks again.

 

Thanks Deej.

Hatto I haven't touched the carby yet apart from admiring it you guys will know all about it when I do. I dont get much spare time and when I do I'm too tired to do much [:'(]
cheers

 

How did the front go?

 

Hey man, nice write up. Where did you order the stainless steel lines?

 

KLXer, I haven't had time to do the front yet, I should get it done this weekend

EJ, email b_jblue@sbcglobal.netthe front is $54.50 and the rear is $33 you need to add frieght to those.

Cheers