Galfer Braided Brake Lines

[ghostler]

Hello all. Now completing my Galfer braided brake line installation and overhaul of all front brake cylinders on my 2001 XII. I got the lines from Amazon:

http://www.amazon.com/gp/product/B00OBPJEUC for $89 US and free shipping. It says for 1987 to 1993, but I saw no reason not to use on my 2001 and it fits.

Harbor Freight Snap Ring Pliers #60531 for $4 made disassembly of the master cylinder easy.

http://www.harborfreight.com/snap-ring- ... 60531.html

Note, using an awl, I rotated the snap ring toward the brake handle cutout notch for more clearance so pliers could fit. Using the smallest jaw pins and a good light source for visibility, after working the pins into the snap ring holes, it was out in a jiffy. Tool is light duty and if I were doing this for a living, would opt for the best, but for the home mechanic, it is a God send.

I removed the old brake line in its entirety including the hose splitter. Wrapping the lines with high voltage electrical tape for cushion and protection, I used universal strap and short bolts to hold lines to bottom of triple tree.

These new lines are neat in that they provide direct fluid straight from the master cylinder. Also, they have a lifetime warranty. Kawasaki owner manual states to replace brake lines every 4 years and overhaul the master cylinder and calipers every 2 years. I don't know who all do that in reality.

[Mr Jensee]

Looks good! I need to do that to my bike. I still have the originals on it and it is 14 years old now. Did they have the rear line available as well?

[Tonyvdb]

Does this also improve the breaking power on the bike?

[voyager55]

Nor Cal Voyagers have steel brake lines for the Voyager at the bottom of this page

http://www.amervoyassoc.org/index.php" onclick="window.open(this.href);return false;

[ghostler]

Looks good! I need to do that to my bike. I still have the originals on it and it is 14 years old now. Did they have the rear line available as well?

Yes, here:

http://www.amazon.com/gp/product/B00NH6W9PS
Kawasaki 1987-1993 ZG1200 Voyager XII Galfer Rear Stainless Steel Braided Brake Line Kit, $50 and free shipping.

Does this also improve the breaking power on the bike?

Braided steel lines don't flex like the rubber ones, so braking is more positive. I've bled the lines the manual hard way (pumping master cylinder, hold, release bleed cock, tighten cock, check master level & top, repeat umteen times. Still got an air bubble somewhere, so I'll re-bleed with my HF pneumatic bleed kit (1st time use).

I took a 1.5" long piece of 5/16" auto fuel line, split it lengthwise, used 2 nylon wire ties to hold in place at the mount above the caliper. Still rethinking the lower triple tree mount and chafe protection at the handle bar.

I've run out of time tonight, so will resume soon.

[chicagorandy]

Us '86 owners will just have to wait I guess.

I asked on Amazon if they will work on mine and was told no. Odd since the bikes share the same parts for MC and brake lines?

[ghostler]

Nor Cal Voyagers have steel brake lines for the Voyager at the bottom of this page http://www.amervoyassoc.org/index.php" onclick="window.open(this.href);return false;

I wasn't aware of this option. Reason why I went this route was due to cost. I gathered they were clearing out old stock.

Us '86 owners will just have to wait I guess. I asked on Amazon if they will work on mine and was told no. Odd since the bikes share the same parts for MC and brake lines?

Ron Ayers doesn't have 1986 XII listed, so I went to Bike Bandit.

For the top hose:
1986 Fiche #43059: HOSE-BRAKE,FR, Bike Bandit #819368, $78.64
2001 Fiche #43059: HOSE-BRAKE,FR, Bike Bandit #820530, $86.93

Bottom hoses:
1986 Fiche #43059A: HOSE-BRAKE,FR, Bike Bandit #819392, $78.64
2001 Fiche #43059A: HOSE-BRAKE,FR, Bike Bandit #820531, $86.93

Bike Bandit uses their own numbering system instead of OEM, but it shows as 2 different parts. I don't know if in fact they are the same or not. There are differences in the fork and strut assemblies between the 1987 and other years. I don't know if there may be differences in lengths, which might affect hose lengths or other ergonomics (fitting bends, different sized banjo fitting, etc.).

Nor Cal Voyagers have steel brake lines for the Voyager at the bottom of this page http://www.amervoyassoc.org/index.php" onclick="window.open(this.href);return false;

Post edit 17 Sep, 07:59am: Just wanted to add that if one were to attempt purchasing OEM hose parts, Nor Cal would be a good way to go, as one would have already spent $237 just for the front hoses and the braided steel have a life time warranty versus the implied 4 years (see owners manual - servicing) for the OEM rubber ones.

[chicagorandy]

I compared parts using Partzilla.com - they use the same hose numbers for both years 86 and 87.

[chevyman1]

Looks good! I need to do that to my bike. I still have the originals on it and it is 14 years old now. Did they have the rear line available as well?

Yes, here:

http://www.amazon.com/gp/product/B00NH6W9PS
Kawasaki 1987-1993 ZG1200 Voyager XII Galfer Rear Stainless Steel Braided Brake Line Kit, $50 and free shipping.

Does this also improve the breaking power on the bike?

Braided steel lines don't flex like the rubber ones, so braking is more positive. I've bled the lines the manual hard way (pumping master cylinder, hold, release bleed cock, tighten cock, check master level & top, repeat umteen times. Still got an air bubble somewhere, so I'll re-bleed with my HF pneumatic bleed kit (1st time use).

I took a 1.5" long piece of 5/16" auto fuel line, split it lengthwise, used 2 nylon wire ties to hold in place at the mount above the caliper. Still rethinking the lower triple tree mount and chafe protection at the handle bar.

I've run out of time tonight, so will resume soon.

A lot of times there's a air bubble gets trapped in the banjo fitting's and they can be hard to get out.

[ghostler]

I compared parts using Partzilla.com - they use the same hose numbers for both years 86 and 87.

For me, it was mind over matter. If I didn't mind, it didn't matter. I didn't contact them, just did my research for my 2001 similar to you and ordered it. It is up to you. I don't know enough to say whether purchase is a safe bet for you or not.

I've bled the lines the manual hard way (pumping master cylinder, hold, release bleed cock, tighten cock, check master level & top, repeat umteen times. Still got an air bubble somewhere, so I'll re-bleed with my HF pneumatic bleed kit (1st time use).

A lot of times there's a air bubble gets trapped in the banjo fitting's and they can be hard to get out.

Thanks, I'm giving the HF bleeder a shot, see if I get that last bubble out.