brake lines ..a setback

[madmax-im]

I'm trying to replace the stock brake lines on my '81 Special but I have run into a setback...while disconnecting the brake line from the front reservior wasn't a problem,when I went to disconnect the other end where the 2 lower lines also connect into a fitting...I find my way blocked by this front fork brace that seems to be attatched to the steering head.The banjo bolts are visible but i cannot get a tool on it with any room to exert leverage.So how do i get access to this area?I took some lousy pics ...see attatched

[XSPastor]

Pix are a little blurry. I'll look at mine when I get home - rainy today.

I have that decorative fork cover too. The two holes are for a yamaha emblem. I have an extra if you want one... But I digress. On to the problem at hand.

How about a socket on an extension with a u-joint?

[egsols]

On mine I took out the bolt holding on the splitter then removed the banjos and lines.

I believe there is only one bolt holding the splitter on and it aligns with a post where normally another bolt would be.

Put the new lines back on the splitter, not tightening the banjos too much.

Put the splitter back in place to check alignment of banjos. When I had the alignment right, tightened them to splitter then reinstalled splitter.

It wasn't easy and a few choice words were muttered before all was said and done. Needs lots of patience.

[madmax-im]

Originally posted by egsols
On mine I took out the bolt holding on the splitter then removed the banjos and lines.

I believe there is only one bolt holding the splitter on and it aligns with a post where normally another bolt would be.

Put the new lines back on the splitter, not tightening the banjos too much.

Put the splitter back in place to check alignment of banjos. When I had the alignment right, tightened them to splitter then reinstalled splitter.

It wasn't easy and a few choice words were muttered before all was said and done. Needs lots of patience.

egsols..
Ok this is what I wanted to know...hopefully this will work on my '81
XSPastor..Thanks for the offer on the Yam.plate.Orig.owner took it off to give the bike a no nonsense look...If the hose/splitter assy can be removed by one bolt then that will certainly simplify matters.Thanks for the suggestions..

[egsols]

I think it is only one bolt but getting it back in is a real chore!

[XSPastor]

It wasn't easy and a few choice words were muttered before all was said and done. Needs lots of patience.

Ahhh, the voice of experience.

[madmax-im]

better pix

I just took 2 better pix...


If it is one bolt out to get the splitter then I will get it hopefully without too many expleteives...patience is best avirtue not lost...

[madmax-im]

Is this it?

The bolt that holds the splitter?Bolt is to the right of the 2 banjos

[egsols]

Yup that's the bolt ...no. 25

It may be worthwhile to look into bending or modding up a wrench to get the top banjo out. The splitter re-install is really a pain. Trying to get a wrench in on the splitter bolt isn't easy either, I had to pry the shield up slightly while lining up the post and wire loom.

Leave the bottom banjo off until splitter and top banjo re-installed. Also make sure you run the wires and brake line the same way they came off or they will interfere with your steering, especially if you run a fairing later on. (Don't ask how I know)

Here's a pic for your enjoyment,

[madmax-im]

Splitter is out

Well the easy part was taking it out.I actually then reinstalled everything to see just how I am gonna do it...I think it'll be ok...anyways I took another pic of the whole assy paying careful attention to see that the left side brake line is on top and then the right side is on the bottom...

[AlanB]

Hi Madmax-im,

I assume that you know that if you lift the top yoke (triple-tree?) the headlamp ears and that tin cover will just slip up out of the way????

I seem to remember that your bike has sat around a little?... if so, it would be a good time to strip the trees off to grease and service the head bearings.........

You WILL feel the difference, and it will not need done again for a looooong time.

AlanB

[madmax-im]

Originally posted by AlanB
Hi Madmax-im,

I assume that you know that if you lift the top yoke (triple-tree?) the headlamp ears and that tin cover will just slip up out of the way????

I seem to remember that your bike has sat around a little?... if so, it would be a good time to strip the trees off to grease and service the head bearings.........

You WILL feel the difference, and it will not need done again for a looooong time.

AlanB

Hi Alan...dang...nope I didn't know that LOL...I was wondering how the #$#$ that cover was attatched...at first I thought it was attatched by the bolts that hold the front brace onto the forks,but loosening those to no avail...This is not being done to Madmax which BTW has been sitting a bit now...anyways the bike I am now working on is the '81 XS1100SH Streetfighter...the brakes are the only issues this bike has...everything else has been addressed for the most part by the previous,original owner.This bike has not been sitting around and its overall unrestored condition is superb.As for the triple tree Ive never taken one off..you got a pic of the tree?What else has to come off if anything?

[TopCatGr58]

Hey Bennie,

Have you seen this link to the Yamaha Online Parts Fiche site ? You can see exploded views of every part/section of the XS11.

Have you ordered the replacement SS brake lines?? Instead of worrying about the splitter you can order just 2 long lines to run directly from the MC down to each caliper. This can also provide a reduction is overall cost, they usually charge by the line/fitting set, not the actual LENGTH of the line, so with only 2 lines you have 1 less pair/set of fittings to pay for, just use a longer banjo bolt at the MC similar to what's used at the splitter! JAT!
T.C.

[madmax-im]

Originally posted by TopCatGr58
Hey Bennie,

Have you seen this link to the Yamaha Online Parts Fiche site ? You can see exploded views of every part/section of the XS11.

Have you ordered the replacement SS brake lines?? Instead of worrying about the splitter you can order just 2 long lines to run directly from the MC down to each caliper. This can also provide a reduction is overall cost, they usually charge by the line/fitting set, not the actual LENGTH of the line, so with only 2 lines you have 1 less pair/set of fittings to pay for, just use a longer banjo bolt at the MC similar to what's used at the splitter! JAT!
T.C.

Hi TC
It was really great meeting you at XSEast '08...In reading what you've just told me ...has pretty much enlightened me to the fact that I do not need a 3 line Galfer kit.I was going to order it tomorrow but now i will once again talk with the tech at cyclebrakes.com and inquire as to the correct 2 line kit as per your post.It is interesting to note that cyclebrakes.com will make the rear line but it has to be custom ordered.So either I give them the measurements or I can send them the actual brakeline and they'll match it up.Once again I am indebted to you my friend.Thankyou very much!Look forward to seeing everyone next year on this '81 Special.If I am not mistaken '09 is the 30th anniv.of the 1st model year of the XS1100SH (Special),so what could be more fitting to bring to the rally?After seeing all the fine Yamahas,I was kinda sorry I didn't have one of mine there..oh well next yr...!BTW TC.. What length should these lines be? or will they know at cyclebrakes.com?