KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Questions and comments about converting to beefier forks..
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jeff.nelson83
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by jeff.nelson83 »

Looking for options on a front brake hose. I did the klx conversion and i reused my kdx wheel, caliper and hose. My problem is my kdx front brake hose is too long, looking for advise on what to use. Thanks

https://www.facebook.com/photo.php?fbid ... a982101b05
jeff.nelson83
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by jeff.nelson83 »

The link is a picture of the bike and what i am talking about.
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rbates9
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by rbates9 »

Why wouldn't a KLX brake hose work?
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Julien D
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by Julien D »

Doesn't really make sense. How is it routed at the bottom? Can't tell from the pic. The KLX forks should have been longer overall than the stock KDX forks.
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diymirage
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by diymirage »

not buying that it is the line that is at fault
The caliper mounts in the same spot
The master cilynder mounts in the same spot and the distance from the axle to the handle bars is the same
There is NO reason the line would not fit right this time if it did fit right before the fork swap

The way I see it there are only 2 options :
1 the previous owner replaced the stock brake line with the wrong one
2 somewhere along the lines of the conversion you didnt put something back on the way you found it

Got any pics showing the brake line before the conversion ?
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by KDXohio »

are you routing the brake line exactly as it was on the kdx
1990 KDX200 FMF Fatty, Answer VFC silencer, VForce 3 Cage, Wiseco Piston, KX125-J series KYB USD fork conversion, Race tech goldvalves, J series front brake assembly, air-box snorkel removed, Acerbis Headlight, KX450F Front fender, Pro Taper RM bend bars, ASV front Brake lever, MSR Clutch perch and lever, RB Head mod, 36mm PWK carb, Trail Tech Kickstand.
jeff.nelson83
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by jeff.nelson83 »

Here are the pictures

Image

Image

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jeff.nelson83
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by jeff.nelson83 »

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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by KDXGarage »

The brake hose is mounted to the master cylinder at the wrong angle, isn't it? Is there not a pipe that goes through the two tangs??
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by Dekon »

The banjo bolt should be mounted between the tangs on the master cylinder. You can see them in the photo of the master cylinder. Where you have hose going up, it should go straight through the tangs on the bottom, winding up almost parallel to the bars.
jeff.nelson83
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by jeff.nelson83 »

Ok if i move the banjo bolt in between the two tangs what does that do to help me the the length? Also wont that bind the hose when the front forks compress?
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by diymirage »

what they said, it should be attached like this

Image

and the guide ring that you mounted to the bark buster goes on the upper pinch bolt of the left hand fork...like this

Image
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by rbates9 »

DIY, the picture of your bike has both of the line guides on the triple clamps mounted backward. And the brake line is on the outside of the fork leg instead of the inside where it should be.
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by diymirage »

thanks for the tip on the guides, I only had the one bike when I swapped them so I musta not paid attention putting them back on, i'll swap them when I get a chance

as for the brake line routing, that is the KDX caliper and master cylinder with the KX line, it just falls that way naturally
I know some people consider it a hazard to get caught on but if experience has taught me anything i'll get my foot caught before anything else :doh:
newbbewb wrote:DIYmirage has it right.


-1996 KDX 200 woods weapon (converted to 99 green body)
-1996 KDX 200 plated street toy (barney edition)
-2003 Yamaha TTR125-L (wifeys bike)
-1997 KDX 220 project bike
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kawagumby
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KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by kawagumby »

You might want to rethink that....the line is exposed to damage including getting torn from a simple low speed fall, or even snagging brush while you're riding.
1994 KDX200, Beta 200rr, yz125, yz250, kx100 modded for adult, gasgas contact 250.
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by KDXGarage »

Always to the inside.
Thank you for participating on kdxrider.net. :bravo:
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jeff.nelson83
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Re: KLX SWAP DONE, BUT BRAKE IS TOO LONG!

Post by jeff.nelson83 »

Thanks for all the help KDX people! I will try a different routing and place the banjo fitting the master cylinder the right way. I will take picture when done but i feel that instead of one big loop it will be a tight loop.
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