1999 K1200LT-C OEM brake line changeover with Spiegler SS braided

1999 K1200LT-C
OEM brake line changeover with Spiegler SS braided lines.
PROCEDURE GROUP:
PROCEDURE NAME:
Procedures for brake line changeover
PROCEDURE NUMBER:
DATE AUTHORISED:
Feb 2010
Items required prior to use:
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Spiegler ’99 K1200LT brake line kit, includes “T” piece, crush washers, 6 brake lines.
Tools required are 11mm open ended spanner, 14mm open ended spanner, Hex Allen keys, 10mm
socket, Philips screw driver, brake fluid, cleaning/protective rags, speed bleeder, small shifter.
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Introduction
Procedure #1 TASK / STEP
Action
1
Check Spiegler brake line kit for
similarity of hoses before removal of
OEM hoses. New T piece, 16 new
crush washers.
2
Cut and remove cable tie on LHS brake
line connection flexible-to-fixed on lower
part of security bracket attached to fork
leg.
Place protective rags over fork leg,
wheel etc in preparation of spilt brake
fluid.
Procedure #1 TASK / STEP
Action
5
Use 14mm open ended spanner to hold
flexible connection whilst using 11mm
open ended spanner to undo fixed line
fitting on LHS fork leg bracket.
6
Use hex Allen key to undo banjo fitting
on LHS calliper and remove LHS
flexible brake line altogether.
Ensure used copper crush washer is
removed from LHS calliper, change
over copper crush washer from banjo
screw, after cleaning screw itself. Slide
top part of the flexible hose out of the
fork leg securing bracket.
7
8
Slide in new Spiegler brake line through
fork leg securing bracket and fit to LHS
calliper with banjo screw, two new
aluminium crush washers. Do up banjo
screw to full extent but only finger tight.
9
Cut and remove the cable tie on fixed
line LHS, be aware of ABS sensor
cable.
Procedure #1 TASK / STEP
Action
10
Cut and remove the cable tie on fixed
line RHS, be aware of ABS sensor
cable.
11
Using 10mm socket undo the nut
securing the three way T piece attached
to the RHS fork leg.
12
Cut and remove cable tie above “T”
piece.
13
Cut and remove cable tie approx 75100mm on main flexible line from “T”
piece.
14
Cut and remove cable tie on main
flexible line approx 200mm from “T”
piece.
15
Use protective rags to cover wheel
guard etc in preparation to removal of
main flexible line and any spilt brake
fluid left in line.
16
Using a “short” hex Allen Key (similar
¨
Procedure #1 TASK / STEP
Action
size to that used on callipers) reach up
into nose cone area and undo banjo
screw fitting holding main flexible line.
17
Remove banjo screw, and retain copper
crush washers on both sides of the
banjo fitting.
18
Undo plastic clip holding main flexible
line to frame member and pull out into
the open the main flexible line.
19
Undo RHS calliper banjo screw, remove
section of brake line that includes main
flexible line, “T” piece and RHS calliper
flexible line complete. Note orientation
of the main flexible line banjo “bend” as
when the flexible line is installed this
“bend” needs to be the correct way
around.
Procedure #1 TASK / STEP
Action
20
Set out new “T” piece, fixed line, top
flexible line, and RHS calliper flexible
hose.
21
Undo fixed line to old “T” piece Used a
hex Allen key through “T” piece hole to
secure whilst undoing fixed line nut.
Attach fixed line to new “T” piece that is
included in Spiegler kit, finger tight only.
Procedure #1 TASK / STEP
Action
22
Fit new aluminium crush washers to
new Spiegler main flexible line and with
banjo fitting bend correct way around,
install new flexible line up into the nose
cone section. Some fiddling around,
found sat beside wheel with feet
alongside rear wheel ok. Make sure
that crush washer is installed, as can
slip off if not careful. Only sufficient
crush washers are included in kit, no
spares. Ensure banjo fitting is located
in between “stops” when installing
banjo screw. Pix also shows the flexible
coming from the handlebar master
cylinder on top.
23
Finger tight banjo screw on main flexible
line, visual check, ….if ok tighten up this
banjo screw to finished torque.
24
Attach RHS calliper new flexible hose to
new “T” piece. Finger tighten fitting
only.
25
Attach new main flexible line to “T”
piece, finger tighten only.
26
Use new aluminium crush washers and
fit RHS calliper flexible hose to calliper,
finger tighten only.
27
Locate fixed line end into LHS calliper
flexible hose fitting, do up nut all the
way, finger tighten only.
28
Ensure RHS new flexible line is away
from wheel, do up to finished torque
setting
29
Fit new “T” piece to securing screw on
RHS fork leg, fit washer and nut
securely.
30
Tighten to torque setting LHS calliper
flexible hose connection to fixed line.
Procedure #1 TASK / STEP
Action
31
Tighten up to torque setting LHS new
flexible to calliper banjo fittings
32
Tighten to torque setting fixed line to
new “T” piece.
33
Tighten to torque setting main flexible
line to new “T” piece.
34
Tighten to torque setting RHS new
flexible hose to new “T” piece.
35
Install new cable ties starting from LHS
calliper flexible hose connection in
same locations as removal of.
36
To install the new SS brake line from
the handlebar master cylinder, remove
all Tupperware, down to stingray.
37
Remove right side handlebar covers
top, then bottom pieces.
38
Remove left side handlebar covers, top
then bottom pieces.
Procedure #1 TASK / STEP
Action
39
Remove 4 x Philips head screws and
ignition switch centre cover
40
Turn the handlebars to the left. You will
now be able to see where the flexible
from the master cylinder threads
through to the fixed line junction block.
A 14mm open ended spanner is
required here
41
You will also need to cut down a hex
key in order to undo the banjo screw
holding the flexible to the master
cylinder.
42
Remove top of master cylinder reservoir
and empty brake fluid from reservoir
(use a syringe)
Procedure #1 TASK / STEP
Action
43
Undo banjo fitting on master cylinder,
undo 14mm nut on other end of flexible
and remove old rubber flexible line
44
Thread through new SS flexible from
the top, and connect 14mm end, just do
up lightly
45
Fit banjo end to master cylinder, align
flexible in the handle bar “trough” and
do up to correct tightness.
46
Tighten up 14mm nut end of same
flexible line
47
Refit ignition switch centre cover
48
Refit left hand side handlebar covers,
bottom, then top
49
Refit right hand side handlebar covers,
bottom, then top.
50
Top up master cylinder brake fluid
reservoir and bleed system
51
Fit speed bleeder to RHS calliper.
52
Fit protective rags around screen, sting
ray, everywhere…Should you operate
the brake lever (with cover off) without
having the speed bleeder open, a jet of
brake fluid will squirt out on to your
screen/paintwork etc etc
53
Remove handlebar master cylinder
cover and bleed RHS calliper.
Procedure #1 TASK / STEP
Action
54
When doing LHS, this can be a one
person event by using Velcro tape to
hold brake lever etc whilst
opening/closing the bleeder valve.
55
To install the rear brake pedal flexible
you need to have the right side panels
off, plus brake pedal plate, so that the
rear master cylinder is visible
56
Note orientation of low pressure fluid
line from reservoir
57
Use syringe to drain brake fluid from the
rear brake reservoir
58
Need 14mm open ended spanner to
loosen the master cylinder nut,
59
Undo the two (2) allen screws holding
the master cylinder to allow the top
nut/banjo to be removed. Remove
screws and separate master cylinder
from brake plate itself
60
Cut cable tie
Procedure #1 TASK / STEP
Action
Because the other end of this flexible
hose end was done up sooooooo tight,
couldn’t get enough leverage to undo, I
needed to disconnect fixed line junction
block with the flexible still attached, and
hence some more work doing this is
entailed
Remove battery
Remove the two (2) allen screws
holding the battery cover, plus 1 x
nut/screw on side (RHS) securing the
battery holder frame
Undo the fixed line to junction block
where the flexible is connected to
By hook or by crook, massage the
bracket, junction block and rear brake
flexible hose out from the bike….fiddley.
Had to put block in a vice in order to use
an allen key to get the banjo fitting
undone….soooo tight.
Replace bracket back on bike
Procedure #1 TASK / STEP
Action
Check the old against the new flexible
hoses and how the banjo end aligns. I
had to twist around the master cylinder
banjo end a couple of times to make
sure both were the same
Thread through the new SS flexible line
Connect fixed line from ABS unit to the
junction block using 11mm open ended
spanner
Connect new flexible line to this junction
block/bracket piece. Tighten to correct
level
Use 15mm open ended spanner to
attach banjo end to master cylinder,
being aware of low pressure fluid line
orientation. See how the banjo fitting
sits against/near the brake plate when
the banjo screw is being tightened. I
had to undo two times to ensure that the
new flexible line “sat’ just right
Refill the rear brake reservoir and bleed
system
Bleed ABS units whilst you have the
Tupperware off.
Date: