Follow the existing brake lines and determine all the
mounting points; you will need to remove any bolts
holding the lines in place. When all mounting bolts are
removed and drain pans in place, you can now start with
loosening the banjo bolts on the calipers.
Before you start, make sure you have drain pans to
catch the fluid that will drain from the lines. Next, you can
start removing the front wheels and any necessary bodywork that will be in the way; on our 400X we only had to
remove the middle nosepiece.
Lay out the new lines to determine which line goes
where. When you know the placement of the lines, begin
routing them the same way you removed the stock ones.
After the lines and reservoir are fully drained you can
begin removing the stock line from the reservoir and feeding the line through the frame. Keep note of how the stock
line is routed, as you’ll want to route the new lines in the
With the brake lines removed from the calipers, allow
gravity to drain the lines. You can remove the reservoir
cover to speed up the process to drain the fluid. This may
take 5–10 minutes to fully drain.
To attach the lines to the reservoir you will want to install
one brass crush washer on each side of the line fitting.
These crush washers act as gaskets to prevent the banjo
bolt from leaking when installed and torqued properly.