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IMPORTANT

The Owner's Manual for this vehicle contains warnings, instructions and other information you must read and fully understand before safely riding or performing maintenance on this vehicle. Always follow the warnings and instructions in Owner's Manual.

Click the link above for the Table Of Contents, or download a full PDF of the Owner Manual in the Owner Support area of Polaris.com.

Brake Line Assembly and Routing

WARNING

When routing brake lines it is critical that you keep all brake lines away from any surfaces, such as engine or exhaust, that can become hot while operating the vehicle. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

NOTICE

All images in the Brake Line Assembly and Routing section show a Honda® model and are provided for reference ONLY.

Kawasaki® Models: Brake Line Assembly and Routing

  1. Prevent slack in the brake line while fastening the brake line to the top and the bottom of the strut rod with provided cable ties in the locations D indicated in the image below.

  2. Run the brake line A forward under the bottom of the gas tank along the main frame of the bike towards the bike’s front neck-tube. Make sure there is a minimum of one inch of clearance between the brake line and the lower head set turning stop posts G to prevent the brake line from being pinched.

  3. Place another cable tie F around the brake line fastening it to the bike’s throttle cable keeper bracket E. The remaining brake line can free hang up to the master cylinder mounted on the right handle bar.

  4. Adjust the pitch of the brake lever, ensuring it is easily reached and easy to pull.

  5. Tighten the brake lever perch hand tight being careful to not strip the mounting perch threads. If needed, you can loop any remaining slack in the brake line in between the right fork tube upper and the neck-tube of the bike frame as seen in the photo below. (Honda® model shown for reference).

    WARNING

    When routing brake lines, make sure there is a minimum of one inch of clearance between the brake line A and the lower head set turning stop posts G to prevent the brake line from being pinched. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

  6. Ensure all previous steps are complete. Then move on the Drive Chain and Sprocket Assembly instructions.

Yamaha® Models: Brake Line Assembly and Routing

  1. For the Yamaha® TTR models, either run the brake line forward on top of the strut rod or run the break line parallel and against the left hand side of the strut rod.

  2. Secure the brake line to the strut rod with a cable tie located at the top of the strut rod and one at the bottom of the strut rod in a similar fashion to the photo for the Honda® model.

  3. Then feed the brake line and master cylinder to the right side of the motorcycle feeding the brake line between the bike’s upper sub-frame column and the wiring harness brackets on the frame. This will help hold the brake line against the bikes frame and as far away from the exhaust system as possible.

  4. Finally, route the brake line forward towards the front of the motorcycle underneath the motorcycle’s fuel tank. Place another cable tie near the front of the bike securing the brake line to the bikes lower horizontal frame tube.

WARNING

When routing brake lines, make sure there is a minimum of one inch of clearance between the brake line A and the lower head set turning stop posts G to prevent the brake line from being pinched. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

  1. Ensure all previous steps are complete. Then move on to the Drive Chain and Sprocket Assembly instructions.

Honda® Models: Brake Line Assembly and Routing

  1. Remove the two rear gas tank bolts H and loosen the front tank bolt on the bike. Lift up on the rear of the gas tank giving yourself enough room to feed the brake line and master cylinder over top of the rear right sub-frame tubing of the bike and under the gas tank as indicated in the image I

  2. Feed the brake line forward under the bottom of the gas tank along the main frame of the bike.

  3. Keeping all of the slack out of the brake line fasten the brake line to the top and the bottom of the strut rod with cable ties as shown J.

  4. Reinstall the two rear gas tank bolts H previously removed and torque to bike manufacturers specification.

  5. Next, torque the front tank bolt to manufacturers specifications. See image for brake line routing reference I.

  1. Near the front of the bike where the brake line is approaching the front neck tube of the bike, cable tie the brake line to the front gas tank frame mount and another cable tie to the bikes frame-mounted wire harness on the bike’s neck tube. See photo below for cable tie locations F.

  2. The remaining brake line can free hang up to the master cylinder mounted on the right handle bar.

  3. Adjust the pitch of the brake lever, ensuring it is easily reached and easy to pull.

  4. Tighten the brake lever perch hand tight being careful to not strip the mounting perch threads.

    WARNING

    When routing brake lines, make sure there is a minimum of one inch of clearance between the brake line A and the lower head set turning stop posts G to prevent the brake line from being pinched. Failure to comply will adversely affect the vehicles brake system and may lead to severe injury or death.

  5. Ensure all previous steps are complete. Then move on to the Drive Chain and Sprocket Assembly instructions.

Parent topic: Installation Instructions