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Rank: Canyon Carver
Groups: Member
Joined: 5/3/2008
Posts: 48
Location: Southeastern PA
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I need to replace the brake lines on my 550. I'm ready to buy a set of custom Galfer lines with dual front lines to replace the stock setup. Is this the best option?
Also, I cant seem to find anywhere whether I need the banjo bolts with fine (1.0mm) or coarse (1.25mm) threads. Anyone happen to know?
Also, when I replace the lines should I rebuild the master cylinder at the same time?
Thanks.
1990 Zephyr 550 - purchased in 2007 with 3725 original miles.
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Rank: n00b
Groups: Member
Joined: 4/27/2008
Posts: 16
Location: NY
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I haven't had Galfer do any for me , but I've seen several posts where people were very satisfied with them. IIRC you should send Galfer everything (lines and banjos) that you want replaced .
1990 ZR550 , all stock , 7500mi . Several older GPz and KZ550 twin shockers too http://s163.photobucket.com/albums/t289/mg15_photos/ Link to some bike photos
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Rank: Administrator
Groups: Administration
Joined: 4/23/2008
Posts: 222
Location: Catskill Mtns.
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I have had Galfer do lines twice. Both times they did two-line replacements "racing-style", which eliminate the splitter, and have both lines going all the way to the master. I simply measured the stock lines, I believe I added an inch or two to make sure I had sufficient slack, and was very careful to describe the shape of the banjos at the caliper end. They're less important at the master cylinder end, because you have more leeway in how you angle them while assembling. If you want to do a two-line kit, let me know and I'll dig up the specs on the last set I had made up. They're currently on my GF's Zephyr, as she has needed hers to get back and forth to school, and I've been more of a homebody over the past year, so my Daphne has been donating parts as needed to keep her running. Now I have to sell off a few more bigger things in the inventory to get the rest of the engine internals shipped out to us, as my GF sort of under-oiled her motor about a year ago and has had a major project under a tarp in the carport since then. :D But when she's done, she'll be able to say she rebuilt a broken motorcycle engine and made it better than new. :D
azraphale attached the following image(s):
| 1990 Kawasaki Zephyr 615 (Daphne) -=- 1986 Kawa Ninja 250 (stolen) | | The Motorcycle Fuel Injection Handbook -=- http://tinyurl.com/297abo |
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Rank: Canyon Carver
Groups: Member
Joined: 5/3/2008
Posts: 48
Location: Southeastern PA
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Yeah, I am planning on the 2 line kit at the front. The way I see it, there's 3 less connections to have issues with (plus removing the splitter take weight off the front end making it easier to wheelie  ) I measured out what I think I need with a length of vacuum line and this is what I came up with: Front Left: 32" Front Right: 28-1/2" Rear: 18" It looked to me like all 3 lines need the 20° end at the caliper ("C" on Galfer's form) It also looked like the master cylinder end of the rear line is also a 20°. On the fronts, I was planning a 12° on one line and a 20° on the other. I figured this would make it easier to keep the 2 from getting in the way of each other (although it looks like you had no trouble with straight ends). I would appreciate if you can check what you ordered to see how close I am. Also, which bolts did you get (fine or coarse) and should I rebuild my Master cylinder when I do the lines?
1990 Zephyr 550 - purchased in 2007 with 3725 original miles.
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Rank: MSF graduate
Groups: Member
Joined: 6/7/2008
Posts: 45
Location: Delaware Ohio
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azraphale wrote:I have had Galfer do lines twice. Both times they did two-line replacements "racing-style", which eliminate the splitter, and have both lines going all the way to the master. I simply measured the stock lines, I believe I added an inch or two to make sure I had sufficient slack, and was very careful to describe the shape of the banjos at the caliper end. They're less important at the master cylinder end, because you have more leeway in how you angle them while assembling.
If you want to do a two-line kit, let me know and I'll dig up the specs on the last set I had made up. They're currently on my GF's Zephyr, as she has needed hers to get back and forth to school, and I've been more of a homebody over the past year, so my Daphne has been donating parts as needed to keep her running. Now I have to sell off a few more bigger things in the inventory to get the rest of the engine internals shipped out to us, as my GF sort of under-oiled her motor about a year ago and has had a major project under a tarp in the carport since then. :D But when she's done, she'll be able to say she rebuilt a broken motorcycle engine and made it better than new. :D Another school of thought... I am considering doing the simple "jumper" line similar to that of the newer ZXs. Run one line down to the right caliper then use a double banjo bolt and run another line from the right to the left caliper, over the fender. It's a clean installation I've used before back in 1989 to hook all the calipers together on a Gold Wing, to make one hand lever work all three calipers (using a proper sized master cylinder of course). It does make some sense in that it is an economical use of space and brake hose. It is easy to run one line down from the master cylinder through the space behind the headlight and the ferrules on the fender should allow two braided lines to fit.
Mark - klx678 Delaware Ohio 1990 Kawasaki Zephyr 550 mostly stock - if I wanted faster I'd have bought faster 1995 Kawasaki KLX650 with a big bore Vulcan piston 678cc, a pipe, and Dial-A-Jet 1978 Yamaha SR500 eventually to be a 60's style flattrack look street tracker 1967or so Bultaco M27 Sherpa T - first bike I bought, 1971.
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Rank: MSF graduate
Groups: Member
Joined: 8/3/2008
Posts: 29
Location: Milwaukee
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I have access to a local shop called Pegasus racing that does all sorts of race car fabrications. They did a few SS oil lines for my friends Civic. Was tossing around the idea of over the winter to just pull the lines and have them fab up some SS units.
1990 ZR550
1997 TL1000S
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Rank: MSF graduate
Groups: Member
Joined: 8/3/2008
Posts: 29
Location: Milwaukee
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Pegasus racing link http://www.pegasusautoracing.com/
1990 ZR550 1997 TL1000S
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