Removing front brake lines/hoses
Preparatory work
- Remove left and right fairing side sections.
- Remove the left-hand battery cover.
Warning: Comply with safety precautions when handling or working with fuel; note that the fuel lines are pressurised.
- Remove fuel tank.
See Group 16.
- Remove securing screws (arrows) and remove retaining plate for plug connectors.
Caution: Do not allow brake fluid to come into contact with painted parts of the motorcycle, because brake fluid destroys paint. Wrap cloths around the ends of the pressure lines to prevent residual brake fluid escaping.
- Drain the brake system.
- Open cable ties securing brake hoses, as necessary.
- Disconnect brake lines (arrows) from ABS pressure modulator.
Brake lines under fuel tank
- Remove holder (arrow) for brake lines from main frame.
- Remove retaining plate (3) for brake lines at front of main frame.
- Disconnect brake lines (1) and remove.
Brake line/hose to telescopic fork
- Remove the brake callipers.
- Disconnect the brake hoses from the brake callipers.
Caution: Screws (arrows) for retaining plates are secured with thread-locking compound. Carefully heat the securing screws; take care not to damage the socket heads when removing the screws.
- Remove screw securing retaining plate (5) of left brake line/hose to front fork.
- Remove securing screw (4) from holder for brake distributor.
- Remove retaining plate for brake distributor, if necessary.
- Remove banjo bolt (2) from retaining plate (3) and remove brake line/hose.
Brake hose to handlebar
- Remove left and right handlebar trim.
See Group 46.
- Remove cover of fork bridge.
- Turn the brake fitting until the banjo bolt of the brake fluid reservoir is accessible.
- Disconnect the brake hose from the brake fluid reservoir.
- Disconnect brake lines (1) from retaining plate (3).
- Remove banjo bolt (2).
- Carefully pull brake hose down and remove.
- Remove screw securing retaining plate (3) to main frame and remove retaining plate complete with brake hose.
Installing front brake lines/hoses
- Installation is the reverse of the removal procedure: pay particular attention to the following.
Caution: Always secure the brake hose with stop plate to the fork slider tube.
Caution: Replace the sealing rings of the brake line/hose. Secure the brake hose to the handlebar fitting in such a way that it does not rub or become kinked when the handlebar is turned.
- When connecting the brake hose to the handlebar fitting, hold the hose against the stop (arrow).
- Use a cable tie to secure the brake hose to the handlebar at the bottom to ensure clearance for the throttle cables.
- Fill and bleed the brake system.
See Group 00.
- Brake fluid grade — DOT 4
Tightening torques:
- Brake hose to brake lever fitting — 18 Nm
- Union, brake hose and brake line — 18 Nm
- Brake line to ABS pressure modulator — 18 Nm
- Brake line to frame M 5 — 4 Nm
- Brake line to frame M 6 — 9 Nm
- Brake distributor to retaining plate — 9 Nm
- Retainer plate to slider tube — 4 Nm (clean thread + Loctite 243)
- Brake calliper to fork slider tube — 40 Nm
- Bleed screw — 10 Nm
- Grubscrew in filler adapter — 10 Nm