DR650 Front Braided Brake Line

G'day guys, I replace the front brake lines on MAX the DR650 with new Steel Braided ones! Hope you enjoy :-) Cheers... Mark
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[@systemadministrator1845]

Nice watch to focus my mind ahead of changing my own lines. Thank you for not editing out your mistakes! Not sure if anyone else mentioned this but it looks to me like the reason you had this problem in the first place is that the brake line was exiting the master cylinder at 90-degrees (parallel to the crossbar) instead of at 45-degrees (looping above the crossbar). This moves the free-play for you brake line from the handlebar area to the fork. Allowing it to touch the tire which should not happen. If you haven't already done so, please check your new line and adjust it upward to 45-degrees as needed. The apex of the loop from master cylinder to first clamp heading downward should be higher than the crossbar. Happy Riding!!!

[@LS-uv9gg]

One thing to note; braided steel lines are super abrasive if they rub up against anything! Make sure when you turn the handlebars, any spots along the line that might rub past a bracket, or a speedo housing, or electrical wires etc., have something wrapped around the steel line at that point. "Spiral Wrap" is a super cheap and easy to get thing, used for decades to do exactly that- wrap around braided line to protect both the hose, and items that the hose might touch.

[@BikerBits]

Nice one... Thanks for the heads up! 👍

[@Cheesebomb32]

Just a friendly tip. When you have a tight bolt, don't hit it with the palm of your hand. It will damage the nerves and blood vessels. Better to go out and buy a good set of long handled ring spanners and get the leverage. Love the Channel. Luke

[@denism5008]

Hi Mark, Eventually you got there! To improve the brake feel further by getting the last small air bubbles out of the line, try and do the following: 1. Press the brake with your hand and tie a zipper round the grip and brake lever so that it is in the depressed position (basically, brake on). Leave this overnight as the valve in the master cylinder will stay open and air from the brake line and brake calliper will evacuate overnight. You can also tap the brake line with your hand for a minute to encourage the trapped bubbles to come to the surface. 2. Next day, give the line another tap for a minute and then remove the zip line! 3. Please double check the specified torque on the banjo bolts! This is CRITICALITY important as they can come loose due to vibrations! 4. Next time you bleed the brakes don't loosen the bleed nipple too much as this creates a gap which sucks the air in the line, quarter turn is enough. I probably wouldn't use the machine anyway, do manually, it's easier. This will give you a very crisp feel!

[@BikerBits]

Thanks heaps! 😃👍

[@jamesjaudon4180]

Very good upgrade. It looked to me like the bleeder pump was "Over Kill" of the small motorcycle system. It was pumping it dry faster than you could control it. Refilling & bleeding the system should be easier when you do the rear. Something that might help. Take that big syringe you had, add a lengh of flexabel hoes (1/4') and fill the system through the bleeder valve. then close the bleeder valve. Pump up the brakes, then bleed off the air bubbles. Usually only takes a couple of pump & bleeds. Jim Jaudon Mescal, AZ

[@BikerBits]

Thanks mate! 👍

[@Mr.XRED1976]

You absolutely smashed it well done Mark , I enjoy watching your real down to earth content its what gives your content the spark that people are looking for keep it up Rock on.

[@BikerBits]

Thanks heaps Wade! 😃👍

[@dodger0101]

Hi Mark, Great video :) I just replaced the brake lines on my old BMW and I tried something new when filling the brake fluid. I went the opposite way. I used a large syringe to push the fluid from the caliper to the master cylinder. I worked pretty good. Because they were new lines there was still a bit of air in the lines, but a quick bleed the next day did the trick.

[@BikerBits]

Brilliant and good Onya! 👍

[@robertsmith7130]

Hello from the USA. Just a note to say how much I enjoy your channel. I’m 71 and ride a 2017 Versys 300 with many mods for Adventure riding. Hopefully I will send you a picture soon. Keep up the great effort as you have made a huge difference to me. A little bit of motivation to throw these old legs over the bike and go ride is very appropriated!

[@BikerBits]

G'day Robert, great to hear mate and good Onya! 👍😃

[@Bowlin01]

A real LOL here when you said ...."I think I have enough skill and knowledge to do this job"....and me thinking back to the 'stove flare-up incident' 🤣😂🤣

[@BikerBits]

LOL 🤣

[@jasonsmith4137]

My wife keeps saying ‘he can here you’ as I’m shouting too much pressure, fill the reservoir up higher’ lol. That’s why the hand squeeze suckers are better for bikes and even then two people are advised so ones topping up.

[@BikerBits]

LOL 🤣

[@mrwill1969]

Mate that's a flash looking upgrade . Thanks for the Friday night viewing , awesome job on the camera work to mate . Cheer's 👍

[@BikerBits]

Thanks Will 😃

[@michaelpowsey]

G`day Mark, bonus video on a Friday is always welcome, made a nice break with a cuppa coffee.

[@BikerBits]

Great to hear Michael! 😃

[@paulwood7798]

LOL. Mark being Mark.

[@BikerBits]

Yep 🤣

[@michaelhicks2973]

at least you gave it a good fluid flush lol just changing your fluid will make a difference

[@BikerBits]

LOL... Sure did! 🤣

[@jrdepew]

Did this upgrade too. Not night and day difference but quality and I feel better having them. Bled old fashioned way. Not hard.

[@BikerBits]

Good Onya mate! 👍

[@MrAlmar07]

Nice one Mark. This'll go nicely with a cuppa after the school drops!! Ha. Awrabesht mate. 😉🏴󠁧󠁢󠁳󠁣󠁴󠁿👍

[@BikerBits]

Good Onya Al 👍

[@MrAlmar07]

@@BikerBits Nice & informative video Mark mate. Good to see the bleeder thing getting used. I'd say that saves a good bit of time. Cheers. 😉🏴󠁧󠁢󠁳󠁣󠁴󠁿👍

[@gregorywayland2156]

Great to watch 👍

[@samp5690]

I put the rubber bush on the line below the clamp to keep it off the fork leg. Just with zip ties.

[@BikerBits]

Oh I have done the same thing except on the braided section on the inside of the fork where it touches the fork! Great mines think alike! 😃

[@samp5690]

@@BikerBits Yep - that's what I was trying to describe. 👍

[@magnusconsul]

Hello Mark, another helpful vid, informative, the average person can give this a crack, Well done and thanks for doing this. Stay safe...its getting warmer so hopefully time to get out, cheers

[@BikerBits]

Good Onya David 😃

[@munter10]

Well that was a hoot to watch, as we in the trade say . . "Bloody amateurs" lol. You really need to stay on top of that reservoir, watch it like a hawk!! Another method is to forget the vacuum bleeder, just use a large syringe full of brake fluid with a hose connected to the bleed nipple and squirt the fluid thru the caliper, up the hose and fill the reservoir. Or . . just go to Delboy's vids of the process, he's a right expert on all things mechanical lol, just ask Matt at the Workshop lmao!

[@BikerBits]

LOL 🤣 Good Onya mate! Yeah I'd like to try the reverse syringe method. I've used one to pull air bubbles! 👍

[@bikecommuter24]

I use a manual vacuum pump system for most brakes on motorcycles, it works very well, although with the new ABS systems some of them need a machine to bleed properly just like cars, I prefer simple brake systems, separate front and rear. those linked brake systems could be a pain at times to bleed, those I used the compressor system to bleed. I'm different than most people I try to use the least amount of force to remove bolts and such, I broke way to many fasteners in my career and I got real good with easy outs and extractors. 😆 Before bleeding a rag or towel around the master cylinder prevents those oh sh*t moments, LOL you can even cover it with plastic wrap or cling wrap as some the UK people call it. You are right there all kinds of ways to change out a brake line(s) if I was changing out the brake line I just connected a hose to the brake bleeder and pumped the old fluid out before I removed the original line I put the drain hose into a empty plastic water bottle with a hole punched in the cap works brilliant for that. Tip to get the coners of the master cylinder clean use a camera sensor cleaner swap you can get them on Amazon using those ear cleaning swabs sometimes leave lint behind. 👍 Cheers. PS sometimes you back flush the brake line, ie push fluid into the reservoir, but use a hand pump not a pressurized one, new brake lines can be a pain once it you get the air out. Years ago we cracked the banjo bolt open a bit to let it bleed, but it makes a mess useless you put a plastic bag over it.

[@BikerBits]

Great stuff... Thanks! 👍

[@theninja001]

You were only filling the reservoir to about 70% that was killing me, and it was sucking down to half after 2 seconds!

[@wobblysauce]

Some bikes with dual calipers do 2 lines from the brake res, but some also have a link line/the double banjo, from normally the right caliper to the left one. And generally, unless you have a leaky brake, you note the level of the fluid and bleed the system, and put it back to that level, as when you do pads and push the pistons back it will overfill. Most caliper nipples that I have used only need to be cracked 1/8-1/4turn, any more than that you suck more air in from around the screw. Pump your leaver and get one of your straps to hold it on the in position overnight and if the res is the highest part of the line you get all the bubbles out, but you have that big loop over the middle, could flatten it out/tilt your bike so that part is still the high point. Fluid looked like it needed a change anyway, as most are a clearish type out of a bottle.

[@BikerBits]

Cool Bananas! 👍

[@tommeyer6033]

dude. most helpful vid. I just got my DR braided lines in this week, will be starting on the job in a couple of days. Have you ever done a "tour" of your shop, to show how you have it laid out and why you did it that way? It would be very helpful (to me at least). I'm a "mechanic" like you, but slightly less so. Just moved into a house with excellent shop potential and am now in the design phase, so I'd love to see what you have done. Thanks.

[@BikerBits]

Thanks mate! No I haven't but through the years it has evolved and I do show that in the videos as I go. I Should do a tour... It's a good idea! 👍

[@billcotton1551]

They do look great on the bike Mark. I'm curious to see if the size of the hole in the banjo bolt makes any long term difference.

[@BikerBits]

Yeah will have to wait and see. I went for a ride today with Hal and they were great! 😃

[@calmistheway]

I'm about to do this.... just the front tho.

[@henryhiggins2021]

reverse bleed new brake lines . Palmolive body wash pump bottle connect 5mm clear tube . 1/3 fill the bottle with brake fluid , prime it . crack and connect to the nipple then pump the bottle . keep empty the master when full, pump till the bubbles stop . you will be done in 2 minutes

[@BikerBits]

WOW... I love it! 👍😃

[@henryhiggins2021]

@@BikerBits I can send a pic, can I PM you here ?

[@jasonsmith4137]

Another trick to remove a dodgy Phillip thread bolt without bashing with an impact setup is simply adding a thick red rubber band between the knackered head and the Phillips head bit. Great for when there isn’t a lot of torque involved in loosening

[@BikerBits]

Yeah that is but most of the time it's always the bloody ones that need a lot of torch too! 🤣

[@mrsPatMcGroin]

Have to do a full run down once you have the rear line on, been tossing up wether or not to go braided lines myself

[@BikerBits]

Yep will do! 👍

[@bradsadventures4558]

Hi Mark. Not sure if it has been mentioned but Brake lines in Australia have to be ADR compliant ...They can fail a roadworthy if not. KOR

[@BikerBits]

Cool bananas! 👍

[@wjb2]

tricks for you cut the fingers of disposable gloves put over bango held on with rubber bands or little zip ties better than tissue. Also i hate those vacuum pumps there to powerful for bikes. As you found out , you blink and the reservoir is empty. i often reverse feed with a syringe from caliper to reservoir. Any hoo still great video Mark

[@BikerBits]

Thanks! Brilliant idea 👍

[@MVDBR]

Good job Mark, not a fan myself of bleeding hydraulic lines man I had some trouble with the clutch on my KTM one time, this took me back 😣

[@BikerBits]

Thanks Josh and yeah sometimes things are just a bloody struggle! 😩👍

[@rorystibbs5164]

Good work mate cheers as my Dr and other bikes need the braids

[@BikerBits]

Thanks Rory! 😃

[@davepridmore3019]

love youre videos .. gosh dirty brake fluid....old trick to help....leave a rubber band on your brake handle over night....so stays open at the master cyclinder ... gives better bleed on your brakes.....keep up the great work ....

[@waynettarin]

If you manually force the brake pads in, it will remove any oil in the calliper.

[@BikerBits]

Cool Bananas! 👍

[@henryhartley9993]

Nice one Mark...

[@BikerBits]

Thanks Henry

[@BIG-K]

Very useful. Thanks Mark 👍

[@BikerBits]

My pleasure! 😃

[@BikerBytes]

Great non tutorial tutorial Mark, was thinking of replacing my brake lines also but not sure how. Now I’m in the know, cheers 👍

[@BikerBits]

LOL... Bloody ripper!

[@doniturner5077]

That bleeder is awesome on a car but not on a bike very little fluid on a bike. Great vid looks like me the garage lol. Thank you sir. KOR.

[@BikerBits]

Yeah I think I would have to agree! 😃

[@kathrynnewton5203]

You can also use a reverse bleeder Mark. It uses physics to remove the air as the fluid rises from the SC to the MC. Nice vid keep em coming, we all need to, do/think about, other things now days lol.

[@BikerBits]

Thanks! 😃

[@peter2679]

Forgive my ignorance but what is the SC & MC?

[@andrewpugh8065]

@@peter2679 slave cylinder /master cylinder

[@kathrynnewton5203]

@@andrewpugh8065 *removes remote comms tab from Andrew* lol ty for answering.

[@BrewCityRider]

Nice upgrade Mark. I'll stick with my hand pump MityVac for bleeding brakes 😁 Slow and steady for that job.

[@BikerBits]

Good Onya mate! 😃👍

[@owenrichardson3026]

Thats heaps better!! sweet upgrade mate :)

[@BikerBits]

Yeah rode it today and it's certainly a better feel now! 😃

[@badjuju6563]

You were sucking air through the bleed nipple threads. You only need to crack the thread loose and maybe 1/4 - 1/3 of a turn extra. cheers.

[@BikerBits]

Thanks for that mate! 👍

[@hodge1970ify]

I was wondering my bike don't idol well on chock and till she's warm she don't idol right if I turn the idol up she revevs high and takes long to idol down when driving! Could this b because of the valve tappet settings?

[@BikerBits]

Sorry mate I don't know!

[@hodge1970ify]

@@BikerBits thanks

[@brucefleming1743]

Great one Mark thanks 👍🇦🇺

[@BikerBits]

My pleasure Bruce! 😃👍

[@BigRigRich]

How’s things going in your neck of the woods sir. We here in the states are seeing a lot of unique things going on down under to all you folks.

[@BikerBits]

Yeah we are going great and yes things are CraZy but we just Keep On Keep'n On! 😃👍

[@javierc2726]

All I understood was bloody this bloody that

[@whitedrguy6503]

First thing you must learn, don’t use the open end of a spanner, use the ring end. Second thing, just use a piece of clear tube running into a bottle to bleed the brakes, motorcycles ain’t that big so the master cylinder ain’t that far from the calliper, them new high tech bleeders are handy on a car where the brake pedal, master cylinder and calliper are no where near each other. Keep it simple, it takes about 2 minutes to bleed brakes on a DR. Bloody entertaining viewing. 😂😂😂😂😂😂

[@BikerBits]

Always learning! 👍

[@coobye]

Mark, did you have any trouble with clutch cable length when you put your steering damper on. Mines just past the limit with higher bars and the Ralle Moto steering damper although mine doesn't look any higher than your setup.

[@BikerBits]

No I didn't mate!

[@gregdavis3246]

Hi Mark Did you use DOT4 brake fluid? Do not mix DOT4 with DOT3.

[@BikerBits]

DOT4+

[@andrewheadland50]

Do the back before you take it for a ride, you will notice the difference..KTM's come with braided lines standard 😝

[@danielnz6925]

Funny watch.🤣

[@BikerBits]

Always here to entertain! 🤣

[@garywilbert3099]

I hate bleeding brake lines, I get so PO trying to get brakes to work. 2 people works best

[@BikerBits]

Yep I agree! 😃

[@mstngrides1863]

Hey mark the brake lines are supposed to be bolted on the rear of the forks not the front and on the outside of the fork that’s why they rub on the tires.don’t want to Sound mean but that’s just my experience but awesome videos love the content cheers

[@BikerBits]

Thanks mate, I'll give that a try! 👍😃

[@dk.650]

Nope, the hose does not go on the rear of the forks. Have a look at your DR.

[@loucee569]

You will find that Mark has routed the brake line correctly. This link is from the Suzuki website clearly showing the front brake line. www.suzukimotorcycles.com.au/range/off-road/dr650se/

[@BikerBits]

Yeah I took a look and it all seems to be right and the only good way to do it. Now looking at the link supplied in the comments, it appears I have it correct! Oh what change that makes... Me getting it right! 🤣

[@BikerBits]

Brilliant... Thanks! 👍

[@chicanopatriot4322]

Sound is cutting out

[@BikerBits]

Must be something on your end?

[@tjracingteam]

Sound all good here 👌

[@TheWanderingGeezer]

That bleeding tool is a waste of time.

[@BikerBits]

If you don't try you don't know hey! 😃

[@AParticularIndividual]

Whenever you're working with brake fluid you should really wear gloves and safety glasses. You really don't want that stuff on your skin, and you definitely don't want it in your eyes.

[@bretsnow5058]

Mark that bottom hose guide is on the wrong way round other wise good job

[@BikerBits]

Just checked and you could be right! But if I swap it around it looks like it would be too far out? So I just bent it a little outwards and now the hose goes straight through without touching the sides. THANK YOU 👍

[@bretsnow5058]

@@BikerBits cheers bro i just thought as Shaw as shit it might catch on the front tire the way it was and that would not be a good thing

[@spencervidal3168]

Painful watching you pull air into the line up top.. All ya need to do is watch the reservoir Bro.. It's like hiring the handicapped.

[@OriginalMusic1983]

What's it like living in an authoritarian dictatorship? I feel bad for you man.

[@BikerBits]

It's bloody CraZy... but I just Keep On Keep'n On! 😃