Re: Time for some fun...pics inside
Today I had the chance to install the long lines - have not put on the 2" Rox Risers yet, but will shortly after posting this. Needed to cool down ::008::
Parts needed
1/4" ratchet
3/8" ratchet
torque wrench - i did mine in in. lbs.
razor blade
14mm wrench
17mm wrench
10mm flare nut wrench
6mm hex (i used external hex socket)
14mm socket
1) I started on the clutch side first. Remove the "holder" from the frame by using an 8mm socket. The bolt is sorta hidden, but you can see it if you look at a weird angle. Then, to give yourself more room yet, release the plastic clip holding the group of wires. Either gently pry on it with a little eyeglass screwdriver, or slide it laterally to release. Keep this bolt for the line holder included in the kit as it will require a shorter bolt (step 6)
2) Once the "holder" is removed, I cut the rubber grommet off the brake line to give my 17mm wrench more area to grab onto. It's metal underneath, so don't worry about going too deep and causing a mess (this is the line you're replacing).
3) In the picture below, I've got the 10mm flare wrench on the hard line nut that stays on the bike and goes back to the ABS motor, my fingers are around that thin 17mm nut you will need your wrench for. Pull down on the flare nut wrench and hold the 17mm open end wrench up. It doesn't take a crazy amount of effort, but be sure both wrenches are securely on their appropriate nuts.
Place a bunch of paper towels under here because a small amount of brake fluid will run out.
4) I don't have a lot of pics of this process, but once you loosen that, the 17mm nut spins to separate the lines. Now you go up to the clutch fluid reservoir and use your 6mm allen/hex socket and take the banjo fitting off. Again, put some paper towels around here as when it comes off, fluid will start to drain (small amounts).
Make sure that both washers (inner and outer) on the OEM banjo come off with the line and you don't somehow double washer your long lines in the installation. You will want to make a mental note of the general soft line routing through the fork tubes so the new longer lines follow that same path.
5) Remove the old banjo fitting bolt with a 6mm hex. Keep a paper towel under here as well to catch the small amount of fluid that comes out of the reservoir. Below is my new clutch line hooked up. Make sure there's a copper washer on both sides of the banjo fitting, take your 14mm socket and torque down to 22 ft lbs.
6) Remove the bolt from the square bracket holding the front brake line to the frame. Again, 8mm socket like the clutch line. Keep the bolt as this will be the bolt for the clutch line holder you took off earlier.
7) Continued from step 6 - Same deal here - remove the hard line from the soft line with a 10mm flare and ??mm open end wrench. Get a paper towel under there to catch the drips. Now remove the banjo fitting from the brake reservoir with a 6mm hex and paper towels to catch the brake fluid. My new line installed below.
8) Purge air from new lines. This is the fluid I chose to use.
Simply remove the caps from the reservoirs and slowly pump the lever to let the air come up. You can shake the lines to assist in this process going faster. Just be damn sure you don't allow the reservoir to go empty or you'll have to bleed the line completely. The neat thing about this mod is that you don't have to do a full system bleed, you CAN if you want, but absolutely not necessary.
Thanks to Jaxon for his help on the phone, took almost as long to write this as it did to install the lines knowing what to expect when before I dug in. Glad I did it and love the 2" Rox Risers!
Hasta!
K