Thread: ORGS build up
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Old 09-19-2010, 11:19 AM   #72
x3300 OP
Joined: Mar 2005
Location: San Jose, CA
Oddometer: 170
Brake Line

I needed to make up a long brake line that routes around the big Trail Tech race lamp.

The R1200RT caliper I'm using had a broken off bleeder, so I figured it would be a good time to fix it. I bought a new bleeder and removed the broken stub with a bolt extractor. I heated the caliper around the bleeder with a torch to expand the aluminum.

I got a few different kinds of hose to make up the brake line. Also shown is the bulk braided brake hose.

I used Earl's Speed Flex -3 hose and Speed Seal hose ends to makeup the line. Details of its use have been covered elsewhere. To get some rigidity in the run between the mount at the top of the fork protector and the line guide I used some stiff plastic hose over the brake line.

When the fork compressed a sharp bend was forming at the upper hose end. I was worried that over time the brake hose Teflon liner may fail here due to fatigue so I used some flexible hose over the brake hose there to reduce the the stress. I used some heat shrink tubing to seal the joints and hold things together. The banjo bolts are just OE BMW (M10x1.0x18).

The CRF has a plastic brake line guide that mounts close to the center of the lower triple clamp. It was not possible to use this with the Trail Tech Race Lamp so I made up a guide from aluminum that mounts to the fork upper with a large hose clamp. For a trim look I used a European spec clamp that has the thinner band width.

Here's how the guide mounts to the fork. I made the hole big enough to slide a hose end through, but since there's no split in the guide I'll need to remove a hose end from either the master cylinder or the caliper to get the guide off the line.

After getting the line on and the system bled I found that two of the caliper pistons were sticky, so I took the caliper apart to clean it up and found some build up on those pistons. The seals didn't show any wear so I didn't replace them.

This caliper uses internal dust seals, as apposed to the external seal of the OE R100GS caliper. I think this internal seal design would be effected by dirt riding more than the external seal design.

This photo shows the seal grooves of the caliper body. The inner groves are for the pressure seals, and the outer for the dust seals.

After the cleanup the caliper worked better. Heres a view of the lower line routing.

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