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Old 06-24-2013, 11:14 AM   #1
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800 XC Front 2-line brake upgrade

Hi All,


After seeing this video awhile back...

http://vimeo.com/lostrider/lostrider


I'm seriously considering upgrading the front brake line routing/ configuration on my 2nd XC. I would like to go from a 2-Line over the fender to a 2-line direct basically running separate lines to the master cylinder to each caliper.


As I sit at my desk at work a decent distance from my bike pondering and scheming I searched but could not find this info. I was wondering if any XC owners have gone this route and could share their parts list/distributor they used.


I found this site that looks great as far as information but not sure on lengths and fittings people are successfully running. I would honestly feel better just ordering the custom kit and having a mechanic complete the work as brakes/bleeding is not one of my talents.


I'm pretty sure I'll need:


(1) Double Banjo bolt M10X1.25X31 @ Master Cylinder
(2) Brake lines with Banjo fittings at both ends (Length suggestions??)
(2) Single Banjo Bolt M10X1.25X21
(6) WASHER,15.2 X 10 X 1.0,PLATED


The stock setup has the banjo connectors at each end so I assume I can get the Line made with Banjo's on both ends correct?



Any help is greatly appreciated!! Thanks in advance




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Old 06-24-2013, 01:07 PM   #2
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If you have ABS, then your lines will be different. They need to go to the ABS unit & then go to the brakes. I know this is common sense, but it needs to be said.
It has been done already. I think his name is Birdy or something. I'll look for a link.
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Old 06-24-2013, 01:45 PM   #3
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Quote:
Originally Posted by Rob Dirt View Post
If you have ABS, then your lines will be different. They need to go to the ABS unit & then go to the brakes. I know this is common sense, but it needs to be said.
It has been done already. I think his name is Birdy or something. I'll look for a link.

Please do Rob, thanks in advance man!


EDIT: Looking at the parts break-down I do not see any line running from the ABS to the front...Am I missing something here...??

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Old 06-24-2013, 02:00 PM   #4
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I've thought about this too... decided if I did I would just get the one lower crossover cable longer and swap it out. Would accomplish what you want without all the hassle.. except the brake bleeding.

Edit, there you go, number 3.
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Old 06-24-2013, 02:11 PM   #5
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Wow deep in the Tiger 800 thread....

Still have some questions....Birdy (PM Sent but I'm sure people would love to hear)

Quote:
Originally Posted by Birdy68 View Post
So it's been a while since I last made a post ~ so now's the time to give you an update...

My latest upgrade was due to that UuuuTube video of the F800GS dude that bit the dust when his front fender broke off and the brake cable grabbed the front wheel....

NEW BRAKE LINES!

I went from this:



... to this:









OK - with the NONE ABS models this would be sooooooooooooooo much easier!
A simple two output banjo bolt up at the brake leaver then two brake hoses down to each calliper.

BUT with the ABS, you have to go back to the ABS unit and then a line back the to callipers.
I have a 'T' junction fitted above the radiator where the return line splits to each front calliper. This is the same design as on the Speed Triples.
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Old 06-24-2013, 02:24 PM   #6
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Speed Triple setup mentioned in his post...

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Old 06-25-2013, 03:36 PM   #7
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Please do Rob, thanks in advance man!


EDIT: Looking at the parts break-down I do not see any line running from the ABS to the front...Am I missing something here...??

Looked at the bike last night and I do see the line running to the ABS unit. I guess I could come up with some basic measurements and hope for the best
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Old 06-25-2013, 04:34 PM   #8
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I hit up birdy and he has a few more pics of the set up. With the ABS there is a line from master cylinder to ABS module then to the front. The 3 line setup is the way it is configured but from the ABS module, not the master cylinder. He did have a spring retainer and rubber bushing holding the T fitting borrowing a mount bolt on the upper radiator mount.

I would have this done by now but I'm separated from my bike by 7000 miles. The Army gets in the way of a lot of trip planing but does facilitate the funds for those trips.

I'd love to know what you come up with on line lenght measurements, fitting sizes, and cost. I have a trip planned and see this as a mod that is worth the cost.

I'm sure if you let Spiegler know what your up to they may want to adopt a kit for the tiger so no more guess work for future owners wanting to do the same mod.
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Old 06-26-2013, 08:03 AM   #9
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In the meantime, just unhook the brakelines from the front fender. If the front fender comes off, then it will not pull the brakeline into your tire. Reposition it when you get out of rocks & gravel.
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Old 06-26-2013, 02:44 PM   #10
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Thumb Non ABS dual brake line

I did my non-ABS XC a few weeks ago. I used 22.5 degree bends on the banjos facing the opposite direction (like an S). One line is 42" and the other was 39" in length, from 10mm hole to other 10mm hole. I paid $60 for the pair from ebay, a guy listed as chevotalandcruiser.
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Old 06-26-2013, 02:57 PM   #11
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Quote:
Originally Posted by onetire View Post
I did my non-ABS XC a few weeks ago. I used 22.5 degree bends on the banjos facing the opposite direction (like an S). One line is 42" and the other was 39" in length, from 10mm hole to other 10mm hole. I paid $60 for the pair from ebay, a guy listed as chevotalandcruiser.

Exactly what I was looking for, thanks One!!

Got any pics showing any of this?
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Old 06-26-2013, 03:43 PM   #12
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Talking No pictures yet

I'll take some and post tomorrow.
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Old 06-27-2013, 11:59 AM   #13
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Pics of dual brake lines non ABS Tiger800XC

Here you go:






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Old 06-27-2013, 08:42 PM   #14
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Someone please explain to me why people spend time and money on mods like these. I guess to each his own in this world but I can't for the life if me figure out why people change brake lines that are still perfectly good.

Makes as much sense as those people who change thier oil when it's still 50% good.
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Old 06-28-2013, 12:16 AM   #15
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Quote:
Originally Posted by Rubberlegs View Post
Someone please explain to me why people spend time and money on mods like these. I guess to each his own in this world but I can't for the life if me figure out why people change brake lines that are still perfectly good.

Makes as much sense as those people who change their oil when it's still 50% good.

Have a close look..................no mudguard.

And maybe some folks like freedom of expression?

vive la différence
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