Brake line kits

I have ordered the kit to replace the lines and a set of EBC pads too. A question; Is it possible to just leave the ABS pump unit in place and just pull off the brake lines? parillaguy
 

emeglasson

New Member
Yes, it is definitely possible. You will just have to plan to plug the holes where the brake lines attach with regular bolts. Might be a little messy trying to get the brake fluid out of the box & lines. But definitely no reason you cant do it that way. I believe your ABS light will be permanantly illuminated on your dash....well, at least if you pull the sensor wires too. If you leave the sensor wires in place, I don't think you will get the ABS warning light on the dash.
 

emeglasson

New Member
owspeed,
sorry, I didn't weight the parts specifically. I only weighted everything I have removed total (16.5 pounds so far). I will pull the stuff out and weight it specifically when I get a chance. I believe I saw someone else post that it was in the four or five pound range, which sounds about right to me.
 

owspeed

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Emeglasson,
Thanks for responding.

I'm building my list/spread sheet of items to remove and associated weights (I should just diet).

Can you share the list of items removed for the 16.5lbs?

Thanks,

William
Santa Cruz

owspeed,
sorry, I didn't weight the parts specifically. I only weighted everything I have removed total (16.5 pounds so far). I will pull the stuff out and weight it specifically when I get a chance. I believe I saw someone else post that it was in the four or five pound range, which sounds about right to me.
 

guzz46

New Member
I weighed everything I took off in my new bike thread

http://www.rc390-forum.com/forum/ktm-rc-390-photos/67-bike.html?highlight=bike

But to sum up the major ones

The stock number plate holder weighs 0.98kg, the R&G number plate holder weighs 0.25kg
The rear foot pegs weigh 0.77kg each
Removing the mirrors and end bar weights and going with end bar mirrors will save 1.33kg
The original battery weighs 3.24kg, an Earthx lithium battery weighs 0.6kg
Removing the tool kit will save 0.58kg
The stock muffler weighs 5.2kg, a GPR Powercone weighs 2kg

For a total weight savings of 10kg or 22lbs
 

emeglasson

New Member
Guzz46's response is actually a bit more detailed than mine. But here is what I removed and replaced:
Removed:
mirrors, turn signals, headlight assembly, tool kit, passenger pegs, license plate holder, ABS unit and associated lines, bolts associated with these parts
Replaced:
stock battery with a Shorai, race windscreen (it is lighter), radial master cylinder (probably not much difference from the stock unit)

I have added the following:
front axle sliders, rear pools, larger 320 disc, and left case protector. I'll add frame sliders soon too.
Those adds were factored into the 16.5 pound savings so far. Basically, I just stripped the street stuff off, and prepped it for the track.

I'll get several more pounds (8-10?) from the next items: billet rear sets from Tyga, GP exhaust from Arrow, carbon race tail from Tyga, tail light removal, and side stand removal.

Update: I just installed the Arrow GP silencer & mid pipe; saved another 6 pounds. Also removed the side stand, which was an additional 1.8 pounds. That brings the total to 24.3 pounds shaved.

I'll weight the next parts going on & coming off for a total potential for a track prepped bike.
 
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Treachery

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Sorry, sort of OT, but are the OE lines stainless or kevlar? The OD is so small, I figured they weren't conventional bits.
 

cjwell

Supporting Vendor
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DSC_0004.jpgDSC_0007.jpgDSC_0020.jpgDSC_0002.jpg

Our brake line kit installed with the KTM PowerPart rear sets. Fitment is fine, NOTE the new routing of line at master and reservoir feed line. Pretty straight forward.
 
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These lines hugely improved our braking this weekend.

Note: If you want the speedo to work, you will need to leave the ABS module electrically connected unless a work around exists. The front speed sensor feeds to the ECU via the ABS module.
 

Rodolfo

New Member
Thanks, that is what I wanted to hear.

As some people started to say the original were also steel brake lines, but the braking feel is really not that great, you have to pull really hard to get them to work decently.

Will order asap.

Thanks
 

Wa2fst

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Help clarify a few things please. These line when leaving the ABS in I still have ABS to turn off and on as I please and they will not throw a ABS light the whole time? If I take out the whole ABS system and install these lines then I will have an ABS light on all the time and a non working speedo?
 

guzz46

New Member
Thanks, that is what I wanted to hear.

As some people started to say the original were also steel brake lines, but the braking feel is really not that great, you have to pull really hard to get them to work decently.

Will order asap.

Thanks

I do believe the stock lines are braided, they just have a rubber jacket around them

IMG_20150210_144946.jpg

And for what its worth, my brakes feel great, and don't require much pressure at all, and apart from the brake lever they're completely stock.
 

cjwell

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Help clarify a few things please. These line when leaving the ABS in I still have ABS to turn off and on as I please and they will not throw a ABS light the whole time? If I take out the whole ABS system and install these lines then I will have an ABS light on all the time and a non working speedo?

If leaving the abs unit plugged in electrically speaking and wheel speed sensors the speedo will function as normal, and no check light. You won't have ''abs'' obviously because the lines bypass the modulator unit. If you remove the wheel speed sensors and abs unit you will have no speedo and the abs light on the dash like the cup bikes. If it is a street bike I would leave speed sensors and abs unit, if it is a track bike I remove all the above mentioned.
 

cjwell

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I do believe the stock lines are braided, they just have a rubber jacket around them

View attachment 433

And for what its worth, my brakes feel great, and don't require much pressure at all, and apart from the brake lever they're completely stock.

The stock lines are braided, BUT not all braided lines are created equally :p. Also even though brake fluid is an incompressible liquid, removing a couple feet of line and fluid helps improve feel/line pressure. Braided hose still flexes just drastically less than conventional brake line.
 

Wa2fst

Member
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Thanks cj for clarifying. This is a track bike that may randomly see the street.

What are some install times leaving the abs and doing lines only?
 
Two things; to answer Wa2fst, I removed the stock ABS KTM lines but left the modulator unit in place. Mostly left because I couldn't see an easy way to remove it. It took me a whole day to take enough stuff off the bike to get at the modulator unit and remove the lines then add and bleed the new lines. I am not the fastest and I will admit to a lot of coffee brakes but expect to spend most of a day doing the job.

OK here is my question: the brake line ABS bypass kit from KTMPERFORMANCE.COM came with a a 2" long grey cylinder about the OD of a pen....what the heck is that for????? It also came with a plastic block that I assume is to hold the brake line...but no hint as to where I should put it. parillaguy
 
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