How to remove the ABS brake line on Bonneville T100/T120Updated 2 years ago

HOW TO REMOVE THE FRONT BRAKE LINE

Liquid Cooled Models

The how-to guide is proved for information purposes only.   The guide assumes you have general mechanical knowledge and have the ability to remove and replace components on your motorcycle.  If you have any questions or are not comfortable doing the work contact a professional mechanic. Keep all stock parts from your existing system as some components may be necessary to install your new British Customs Products depending on the application. 

Read through the guide prior to beginning to remove any components.  Always properly support the vehicle with a stand and/or lift when servicing or performing any work. Unstable vehicles my present dangerous conditions and may cause property damage and/or personal injury

Step By Step Guide - How to Remove the Front Brake Line

1. Remove the gas tank (see How to Remove Gas Tank)

2. Remove the Rear Wheel (see How to Remove the Rear Wheel)

3. Remove the Rear Swing Arm (see How to Remove the Swingarm)

4. Remove the right side cover by pulling the side cover away from the bike.  

5. Bleed the front brakes

6. Using a Phillips screwdriver remove the master cylinder cover and verify there is no brake fluid in the front master cylinder reservoir.  

7. Using a 14mm socket remove the banjo bolt from the front master cylinder. Discard the two crush washers.

Note: Have a rag ready to catch any brake fluid that may leak out.  Brake fluid is harmful to the painted parts.  

7. Remove the rubber strap that secures the brake line to the switch wiring. Save the rubber strap for installation.

8. Using a T25 Torx, remove the (2) bolts that secure wire guide to the frame.  Note the routing of the wiring, clutch cable and brake cable for installation.  

9.  Route the brake line to the left-hand side of the bike.  

Note: The routing of the brake line for installation

10.  Disconnect the hard brake line from the clip located on the right side of the frame

11. Using a 5mm Allen remove the (2) bolt and (2) inserts that secure the coolant cover.  Save the hardware for installation.

12.  Using a 12mm remove the banjo bolt from the ABS unit.  Discard the crush washers.  

13. Using a T30 Torx remove the (1) bolt that secures the evaporative canister. Save hardware for installation.

14. Using a 3mm remove the (2) bolts and (2) washers that secure the evaporative canister, located on the right side of the motorcycle. Save hardware for installation 

15. Move the evaporative canister out of the way.   

 16. Route the brake line from the ABS unit to the left side of the bike and remove the hard brake line.  

Note:  Be careful to not bend the line excessively.