Two line Front Brake kit

[EricV]

Eric,

Isn't there a reason for the cross-over line up front? I thought it had to do with proportioning and the Linked Braking we have on this bike. Is this in conjunction with them saying to perform a proper sequence of bleeding due to this? Curious????

Thanks

No, the linking is done via the ABS block, IIRC. The cross over line is merely an extension of the fluid path from the master cylinder to the left caliper, then over to the right caliper. Because brake fluid does not compress, your squeeze at the lever compresses both calipers at the same time. The cross over line is simply a cheap way of getting fluid to that second caliper.

I have seen some systems that have a separate line from the rear brake system to the front calipers, but the Super Ten does not use this type of system. Unlike the FJR, we do not have a separate puck in the caliper that is only compressed by the rear brake hydraulic system.

 

[Brntrt]

Any new developements?????

 

[EricV]

Any new developements?????

Not much. I have a source for crush washers and lines, but the Yamaha brake line clamp I want to use is back ordered for 4-8 weeks, so I'm looking at alternatives. I haven't had time to play with the fender raise yet. I'm also hoping to make something up a little cleaner, but the low profile fittings won't be available for a few weeks or possibly into the new year.

With the current lines, I plan on having some captured 2" segments of fuel line to allow us to clamp the smaller SS lines in the oem brackets. I am unable to source the oem like rubber bushings like Yamaha uses, at least at the moment.

Got side tracked by the Santa Ana winds last week and ended up riding the SO's GS to Vegas for it's service. It's a bit small for me, but as I shift into 6th I hear a 'bad noise' from the tranny. We make it the ~100 miles to Vegas and I tell the service guy about it. When we come back to pick the bike up later in the day, he tells us the tranny is coming apart. Good thing she sprung for the extended warranty. She has 35k on the bike for her first year of ownership.

 

[lbever]

Eric,
Do you have the two brake lines available from the block to the front wheel calipers. I have everything else I need to complete the job.

 

[EricV]

Eric,
Do you have the two brake lines available from the block to the front wheel calipers. I have everything else I need to complete the job.

Sorry for the delayed response. I am waiting on some Yamaha brake line holders for the right side. Back ordered.

I have been waiting on those to have a run of lines made up because I wanted to verify the fit of the lines with the holder being in place. I'm pretty sure they are fine as is though. Just trying to avoid an expensive mistake.

 

[oKLRider]

Reviving an old thread...
::017::

 

[~TABASCO~]

Hell, I screwed around with this for months.. The block is the hold up... I looked in the US, aircraft industry, hydraulic industry, China, Europe, Etc (I was told from each of these folks the part I want is not made, by the 3-4th person I started to believe) and even shelled out cash to have some custom made but they came back and said its a No-Go.... After that I kinda gave up... Even if I found the "magic" part, it would have probably been expensive.

There are some pretty easy ways to rig it up, but its not clean and factory looking, and I don't like that look, so I just kinda dropped it.... There is the short story.....

 

[EricV]

I guess I should chime in here. Just got back home from a month on the road for an Alaska trip, so not fully up to forum speed.

I made and sold about 6 sets of two line kits that replace the junction block under the triple tree and ran two new lines along the oem path of support brackets, then down to the individual calipers. The lines were slightly longer than stock to account for the bend radius of the stiffer stainless steel braided lines. If you were using a raised fender, or not using the oem path of brackets to support the lines, that set was too long and had a lot of extra line in it.

I've had the original set of prototype lines on for something like 60k now w/o issues. One customer opted to not run the lines thru the oem path of support clamps and suffered a leak at the swaged fitting for one of the banjo bolts. The lines are tested to 30,000 psi when made at the hose shop, so it wasn't faulty at manufacture. Never the less, I warrantee'd the item and unfortunately, the shop made a mistake in a fitting and they had to re-make the line and over night it to the customer. I paid for all of that, which eliminated any profits I made from the 6 sets I sold and put me down the rabbit hole in negative figures. At that point, I decided not to continue to offer the two line kits.

I recently cobbed up a high fender bracket and butchered the remains of my oem fender to mount high before heading off to alaska. At that point I also made a short bracket to secure the right side brake line in a similar orientation as the left, to avoid issues. I routed the now too long lines on each side of the high fender and turned the key and left for an 8k mile trip. No issues during the trip, including a LOT of rough pavement, no pavement, Top Of The World Hwy 107 miles of muck, mud, gravel and occasional stretches of pavement in the middle of no where. I'll probably have the lines shortened after I score a set of Jaxon's fork protectors and consider how the lines run with them in place.

Right now, I am not offering a two line kit. However, I may again offer a two line kit, replacing the, (proprietary), junction block and adding two SS braided lines, along with a high fender bracket, (you choose your own fender). I have some work to do in order to price that out, and it may only be on a beta test, trail basis. I'll post in the vendor section when I have something to post about and pictures, prices, etc.

 

[duggram]

Nick Stoltec makes a two brake line kit for the FZ-09. Maybe we could pester him to make one for the S10? Or am I not understanding the issues with making a kit?

 

[EricV]

Go ahead and pester him. Nothing to lose. As I see it, there will need to be two kits, one for people running stock fenders and another for people running custom high mount fenders. I originally made mine up because I saw the YouTube vid of the F800 rider crashing after he sucked a rock into his stock fender, snapping it off, and the brake line caught on the tire knob, causing an abrupt endo crash.

Our fender is secured at the rear as well as the main mounts, so is less likely to do that, as I found out when I broke it at the main mounts, but I still see the elimination of the cross over as a good thing for aggressive riders or anyone wanting a high mount fender.

 

[oKLRider]

I recently cobbed up a high fender bracket and butchered the remains of my oem fender....
....
Right now, I am not offering a two line kit. However, I may again offer a two line kit, replacing the, (proprietary), junction block and adding two SS braided lines, along with a high fender bracket, (you choose your own fender). I have some work to do in order to price that out, and it may only be on a beta test, trail basis. I'll post in the vendor section when I have something to post about and pictures, prices, etc.

Thanks for the update. Did you end up using the bracket template I sent you, and if so, how'd it work out?

 

[~TABASCO~]

Go ahead and pester him. Nothing to lose. As I see it, there will need to be two kits, one for people running stock fenders and another for people running custom high mount fenders. I originally made mine up because I saw the YouTube vid of the F800 rider crashing after he sucked a rock into his stock fender, snapping it off, and the brake line caught on the tire knob, causing an abrupt endo crash.

Our fender is secured at the rear as well as the main mounts, so is less likely to do that, as I found out when I broke it at the main mounts, but I still see the elimination of the cross over as a good thing for aggressive riders or anyone wanting a high mount fender.

I don't think you need two kits... Just have both lines come off the juncture block at the top and each line fall to each caliper... This is how I have mine and has worked fantastic. Then it doesn't matter what someone does to there front fender... As you and I have spoke about, It will depend if someone can fashion the necessary hardware to make that happen again..

 

[oKLRider]

Seems like the setup that WASP did, with his custom machined block, was the simplest...have either of you tried that route?

 

[~TABASCO~]

There ya go... Looks like ya found it ! ::008::

 

[oKLRider]

There ya go... Looks like ya found it ! ::008::

I wish! He has long since fell off the radar, and never offered that kit for sale. :'(

 

[avc8130]

Nick Stoltec makes a two brake line kit for the FZ-09. Maybe we could pester him to make one for the S10? Or am I not understanding the issues with making a kit?

I pestered Nick about a 2-line kit through Speigler. He mentioned it to them and they said they saw no market for such a kit. If we could put together demand for a kit we could definitely change their minds.

Start a list. Who would want a 2-line setup?

ac

 

[~TABASCO~]

I've had six people ask for the set over three years. In my experiance, no demand.

 

[EricV]

Thanks for the update. Did you end up using the bracket template I sent you, and if so, how'd it work out?

No, I fabbed up something with a piece of .125 thick steel I got at Ace hardware. I did it slightly differently, having a spacer in the middle of the bracket, with a longer bolt going into the expansion bushing in the TT tube. So when tightening the center bolt, it snugs the expansion bushing, but also clamps the lower plate solid to the bushing.

I'd like to have a couple made from your template and play with them and may use that as a basis of a 'kit', but not w/o some prior communication with you.

As for how what I cobbed together worked, 8k miles for the trip, some really, really rough roads, lots of gravel and the Top of The World Hwy too, nothing fell off. ::013:: I added a horn relocation hole and am still not completely happy with my brake line routing, but my lines are too long, having been intended to route the oem path before with all the strain relief that gave, (which prevented failures due to lines flopping around).