At approximately 52,200 miles on my PC800, I decided it was time for new tires. I put two brand new Metzeler tires on the bike but found as I put everything back together that the calipers on the front wheel were sticking. one thing led to another and before I had ridden another 100 miles, I installed braided steel brake lines made up by
Fluid Connector Products Inc in Salem. The lines cost about $125 to have built up plus my time and gas money driving up and back. I also replaced all 15 of the crush washers at about $2/each. While I was at it, I rebuilt the master cylinder and calipers. I also rebuilt the clutch slave and master cylinders. In the end, this project cost me about $300 for tires and mounting and $300 for the brake and clutch hydraulic system rebuild. The bike feels amazingly responsive now so I would hazard to say that the expense was totally worth it. Eating Top Ramen the rest of the summer is a small price to pay for safety and performance. In the picture above you can see the old hoses I took off the bike.
I removed a lot of plastic to safely take off and re-install the hydraulic lines.
The new lines taped together with the old lines. I got the two lines that run to the controls lengthened by an inch to compensate for my GenMar bar risers. It ended up being a good decision.
The banjo fittings on the braided stainless steel lines aren’t quite the same as the old ones but they worked well enough. I wrapped the braided stainless steel lines in electrical tape to help avoid damage. Next time I have the bike apart, I am going to put some rubber cushions on the places where the lines can rub metal.
The line to the clutch slave cylinder installed.
I used a thick towel to keep my plastics fresh and preserved. Not a single drop of DOT4 fluid (as far as I can tell), landed anywhere to cause damage.
Lines installed on front wheel.
Bleeding the lines took some work but they’re rock-solid now. For those wondering, this upgrade is TOTALLY worth the money. You will thank yourself when you get it done. And doing it yourself is actually very easy. I was surprised at how painless the whole operation was from start to finish.
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Hi
i’m a firm believer in replacing brake and clutch lines with stainless steel ones. The feedback is great and a lot less squeezing is required to stop…or go.
Anyway, my question to you is this…Did you happen to receive on your bill the length of the brake and clutch lines and even more critically, the degree of bend used in the fittings on each end? No one in my area makes braided lines so I thought I could glean a little info from you regarding this if you have the info.
Cheers, Def
Hi Def,
No I’m afraid I didn’t get that information. There are a few companies that sell stainless steel braided lines for the PC800 online though that others have had good luck with.
Cheers!
Douglas