Separate front brake lines (info needed)

lukasteam

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Good day guys,
I want to change my stock front brake lines to aftermarket . I would like to have two separate lines coming from the block below the triple trees going to each caliper without the "cross-over" line that goes over the fender from left caliper to the right .
Has anybody done this on their ST ? I couldn't find any info on the aftermarket kits for this mod , so maybe somebody already have done this and have the specs. that I could give to Spiegler or Galfer , so they can make me a kit .
Any info would be greatly appreciated !
 

ballisticexchris

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Both Spiegler and Galfer can make any configuration you want. The only reason to do it the way you suggest is do make it easier to bleed the system without removing the calipers. If you go with OEM configuration it's near impossible to bleed the crossover line with the calipers mounted.

You can do this measurement yourself by simply using some wire or string/small rope and run it from the block to your calipers. Just make sure you leave room for handlebar turning lock to lock and suspension travel.
 

EricV

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Good day guys,
I want to change my stock front brake lines to aftermarket . I would like to have two separate lines coming from the block below the triple trees going to each caliper without the "cross-over" line that goes over the fender from left caliper to the right .
Has anybody done this on their ST ? I couldn't find any info on the aftermarket kits for this mod , so maybe somebody already have done this and have the specs. that I could give to Spiegler or Galfer , so they can make me a kit .
Any info would be greatly appreciated !
I did this on my '12 Super Ten because I wanted to raise the fender for more mud clearance. I first did a 2" raise, but with the under headlight mounted aux lights, full compression would hit the fender. (I broke mine twice that way), so I ended up doing a high fender mounted to the bottom of the triple trees which worked well for my needs.

In my case, I went to a hydraulic hose shop that could make up custom brake lines. After some searching of their inventory, we found a junction block with a mounting hole that could be used in place of the OEM one at the triple tree, with the required two lines coming out. It's not a common part and wasn't an exact replacement, having a larger bolt hole than OEM, but it was fine with a washer.

I choose to route the lines much like the OEM, except going to each side with strain relief at the upper forks and at each caliper to the fork. This required longer lines. It's important to decide on your routing and the end orientations to give input to the shop on lengths and orientations of the end fittings. You will very much want to have strain relief at the right side fork near the caliper, similar to the left side to avoid flex at the hose fitting, which will result in a failure if there is no strain relief. (Some Yamaha's use a similar brake line clamp on the right side). At you'll need a short brake banjo bolt where you change the left caliper from two lines to one. (I have several of both of these. PM me with your address and I'll mail you one of each.)

It cost me about $125 to have the lines made, if I recall correctly. I used coated SS braided lines. You can get rubber ones made, but the cost is not significantly cheaper and even though the SS lines have no benefits in terms of brake feel w/o doing an entire kit, (even them minimal with the ABS solenoid in the system), they are more resistant to damage.

I did do a write up on this forum. Here is the original thread when I was making kits and selling them. LINK I stopped because one buyer installed them w/o strain relief and had a failure, which I warrantied with a replacement line, the cost of which completely eliminated all profits from the other sales. Just not worth if for a low profit kit with a small market.

Here is another thread discussing this, with some pictures of WASP Works custom kit that I don't think was ever sold. He made his own custom junction. LINK2

Feel free to PM with questions. I'll answer as I can.
 

~TABASCO~

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Ive been down this road a few times with the Super Tenere. Finding the parts that are built correctly has been an issue. Installing them not hard at all.
 

lukasteam

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Thanks for the info EricV !!! I already have needed banjo bolts , appreciate the offer . Any more info on the block at the triple tree . Do you know the thread size where the block would attach to the hard line ? I have an access to a primitive machine shop I think I could make one . After that only thing left would be the brake likes ...
 

EricV

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I'm a retired machinist, fwiw. The junction block isn't that complicated if you have the correct tooling.

It's been around 9 years since I did this. Let me dig out my records and I'll post what I have. My lines were longer than what others were using because of how I chose to route them for extra strain relief.

I ran them w/o issues for well over 100k miles and as far as I know they are still on the bike with another forum member riding it.
 

EricV

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Public update, I searched my records, but must of tossed all this info in some previous purge of my file cabinet and I couldn't find anything. Sorry to not be of more help in sharing what I did before.
 

EricV

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Some pics I found on my computer still from the original kits I made up.

New junction block to go from hard lines to new SS lines to each caliper with mounting hole.
DSCN1175.JPG
OEM line with junction block on top, new lines on bottom.
DSCN1174.JPG
Better shot showing how one line is the original length to the left caliper.
DSCN1173.JPG
Routing up under the fork trees showing the junction block bolted in place and some of how I secured the lines in similar to OEM fashion for strain relief.
DSCN1176.JPG

Lower strain relief and routing on top of my 2" raised fender.
DSCN1177.JPG
Left side routing and note the piece of rubber fuel line I put around the SS line to hold it in the OE holder.
DSCN1178.JPG
Right side, not showing the OE style metal clamp I later put on to secure the new SS line from flopping around.
DSCN1179.JPG
Later shot that sort of shows the bracket and brake line secured with a zip tie.
0402CAC2-95D9-4E90-90E0-9740F868411E_1_105_c.jpeg

That's all I could find today. Hope it helps others.
 

lukasteam

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Just went through all the pics. Eric . Thanks again , absolutely great info , now armed with a lot of "how to" and can proceed with the project .
Big help !!!
 

EricV

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Please take pictures of what you do, and add to the collective info here for the next rider that wants to do this.
 

ballisticexchris

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The biggest advantage of the way Eric did his is the ease of bleeding system. You no longer have the hassle of the crossover catching air bubbles.
 
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