Ok they're finally done. I would highly recommend this job be done by a pro.I had a
lot of help, & really needed it. My mechanic new that I was planning to do my hoses
this past weekend , so he decided to check things out Friday night which prompted him
to come in Saturday & get the job done right. He was right in doing so, because prior
to his arrival I was looking at the stock lines (nicely laid out on a table) &
contemplating on where & how to start. I took these things off a few weeks ago, so
remembering exactly how to route them is guess work at this point(even with the shop
manual in both English & French versions). But here comes my guy, clears off the table
(much to my surprise), chalks the OEM lines in a corner, & says something to the
regard that they're history. He is a meticulist, & makes it look easy . Believe me
it's not. The brake lines are long & snake their way around the bike. Routing is very
important, & making sure the banjos sit flat with no twist is a chore (angles are
crucial). I highly recommend some form of exterior coating as the lines touch things
in more places than they don't. I used SS line & covered it with black gas line hose ,
which gives it the OEM appearance & I added rubber boots to all the visible banjos. I
also retained all the OEM bracketry & rubber grommets .It was a heck of a lot of work
but the result is worth it. Considering my guy didn't copy the stock lines, the
overall length of the lines came out just about the same as the OEM , give or take an
inch or 2. The OEM clutch line is 47 1\8" banjo to banjo(2banjos,1rubber hose). The SS
clutch line is 48 1\2" banjo to banjo(2banjos ,1 SS line). The front caliper OEM line
is 90" (very hard to measure precisely) banjo to banjo(2 banjos,4 inline
connectors,3rubber hoses,2metal lines). The SS front caliper line is 86 3\4" banjo to
banjo (2 banjos, 1 SS line). The OEM front master hose is 69 1\2" banjo to banjo (2
banjos,2 inline connectors,2 rubber hoses). The SS front master line is 64" banjo to
banjo (2 banjos, 1 SS line). The OEM rear caliper hose is 26 1\2" banjo to banjo (2
banjos, 1 rubber hose). The SS rear caliper line is 27" banjo to banjo (2 banjos, 1 SS
line). The OEM rear master hose is 13" banjo to banjo (2 banjos, 1 rubber hose). The
SS rear master line is 13 1\2" banjo to banjo (2 banjos , 1 SS line).These
measurements are from banjo tip to banjo tip.He eliminated all the inline connectors &
metal hose. Now the tricky part is the angles of all the fittings, this is where a
professional is required, as I can't say precisely what they are.On the rear
reservoir, I haven't found a suitable replacement for the rubber hose that connects it
to the master (other than rubber hose covered with braided line, so I left it stock
for now.My guy is reluctant to reproduce these lines without having the particular
bike in question at hand. Our GTS's braking system is not like any other & therefore
he prefers to be on the safe side & consider it a custom job. I can relate as I was
there . It took all of Saturday to get the lines cut right , routed to satisfaction &
setup with the rubber housing & grommets (we didn't even get to bleed the system yet,
& the OEM lines were already off & the bike stripped down). I got the speed bleeders
to assist in the bleeding dept. as they have come highly recommended in this club. The
final cost for the all the materials involved comes out to $630.90 CAN. I asked my guy
about labor charges when a bike is whole, & he responded with a figure of $300.00 CAN
which included installation & shop supplies.(A tip he suggests is doing this job at
the same time as a spring tune up for example, so you wouldn't be charged twice for
disassembly\reassembly & shop supplies since the bike requires disassembly for either
job). I'm very satisfied with the way things turned out, it's a primo job. Peter Piazza
