I was fiddling with my bike the other day, and I noticed a split in the little rubber “sleeve” that bridges the seam between the top of the protective plastic up-tube on my front brake line to the rubber line coming from the master cylinder. After looking at it for a while, it appears that it was caused by the brake line being improperly routed from the factory.

The line *was* routed underneath the clutch cable. I re-routed it to in front of the clutch cable. I also flipped the upper “hoop” guide that attaches to the triple-clamp, so that the cable moves more freely.

Now, when I ride, I notice the brake line constantly moves up and down with the front suspension. Before; the line was trapped under the clutch cable, and was only able to bend at a right angle where that little rubber sleeve connects the plastic line to the main line from the master cylinder. Hence, the sleeve eventually split.
The sleeve serves no purpose (that I can think of) other than to keep dust and crud from getting into the protective plastic tube, so I just taped it up.

It seems to me that if I left the cable routing as-is, after a while it would have eventually caused issues with the front brake line. Anybody else seem to have the same brake line routing issue? ... Or, was it an isolated event, indicating that the 16 year-old who put the bike together just happened to be on drugs that day?

 

I re routed the brake lines too when I installed the hand guards. Now the lines move freely up and down with the suspension.

 

I did the same as well when I put on new bars.

 

I had the same problem with the stock front brake line sleeve cracking where it bent at 90 degrees. So I freed it up and noticed it bounces around with the suspension which I think is better. Today I am putting on the s/s lines and am looking at options. I will probably just tie wrap to the inside of the fork protector and shoot back and straight down onto lower banjo bolt. It looks like there is enough brake line to route it underneath the fork where the old hard tubing ran, but think that looks vulnerable mounted underneath the fork.

 

old thread i know but i just got a 2009 with under 1000 miles and same deal....

 

Hi Ken, it's a long time ago but I think it worked out well bouncing up when the forks compress. It makes sense that something has to give and to me it's better that there is no repeated flexing of the line. The stainless lines worked out great. I took that bike on WABDR and an 1100 mile loop in oregon and it is a solid performer. I miss it.

 

i am putting ss braided lines on mine.....that trip sounds awesome... my buddy and i are planning to do the TAT....and i am taking the klx.