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Front Stainless Steel Brake Line Install Guide
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Degree of Difficulty: 4
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Tools & parts needed: 1) A set of stainless Steel brake lines 2) Hand Tools 3) Vacuum Gun may be needed 4) Dot 4 brake fluid 5) 2 sets of hands for bleeding(optional)
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Step 1 Remove the old brake lines. There are banjo bolts where the lines go into the calipers and master cylinder(A banjo bolt is a hollow bolt with a hole in it to allow the brake fluid to flow through). Remove the 2 bolts at the calipers. One at a time and carefully let the fluid drain out. Do not let this fluid get on anything. It will destroy paint and other stuff. You will see that each one has two copper washer seals. Discard these as they are not re-usable. You may need to pump the brake lever to get all the fluid out.
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Step 2 Remove the banjo bolt from the master cylinder. Use a shop rag to catch any remaining fluid that might come out when doing this.
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Step 3 Remove the hood. You will see that the lines are routed under the hood and down by the bottom of the steering stem. Then out the a-arms to the calipers. Remove all the bolts that hold them on and remove the lines. The lines will have some fluid in them so be careful where you lay them.
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Step 4 Remove the master cylinder lid.
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Tip I have seen 2 different style line set ups. One using a splitter block like the stock lines have and one where there are 2 separate lines that run from the master cylinder to the calipers. This set up has a longer banjo bolt at the master cylinder with 2 holes in it. I have the 2 separate lines. I am not sure if one is better than the other though.
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Step 5 Install the lines the same way the stock ones came out. You may need to route them a little different and some of the hold downs may not be usable with the aftermarket lines. Use plastic wire ties when needed. You can also buy billet brake line holders for the a-arms. Make sure you use all new copper sealing washers and tighten the bolts to spec.
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Step 6 Once your lines are installed, bolts tightened, and routed properly. Making sure there is no interference when turning the steering. You are ready to start bleeding.
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Step 7 Start bleeding. Fill the master cylinder with fluid. Make sure to keep it full at all times during this procedure. Starting with the left side caliper, loosen the bleeder. Start pumping the brake lever until fluid flows out and then tighten the bleeder. Do the same with the right side. Remember to keep the master full. Now go back to the left side. Start pumping the lever again. Hold the lever down and crack open the bleeder. You should get some spurts of air and then some fluid will flow out. With the lever still held down, tighten the bleeder. Keep doing this until the lever gets firm. The more you do it the more air you will get out. The more air you get out, the better the brakes will perform. Ideally you want all the air out but I think that is impossible. If you are lucky, that is it, you are done.
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Tip Since the system is empty of fluid and full of air, bleeding could take a while and be very hard to get a firm lever. In fact I bled for about 45 minutes before I even started getting a firm lever. Even then I could not get a firm lever I was happy with. The system was air locked. Tapping on the caliper very gently with a ball peen hammer can sometimes loosen up the air bubbles. This turned out to be a long night for me but I finally got a pedal that I could live with for the next day's ride. I would be back to address this problem next week.
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Step 8 So I borrowed my friends vacuum gun the next week. With this set up properly and the can in place, it can be used like a suction gun or "power bleeder". Simply attach the hose to the open brake bleeder and start pumping. It sucks fluid and air through the system and will usually leave no air bubbles. Keep the master cylinder full.
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Thanks to the guys at Desert Sand ATV for supplying the brake line kit for this project. Click on the image below to be directed to their web-site to order yours
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This site was developed and maintained by Jeff Poole. Honda, TRX450R, Fourtrax, and all other Honda related terms are property of Honda America Corporation.
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