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Discussion Starter #1
So I lost my third brake line last night. Number one was the front master cylinder line which developed a pin-hole. Number two was the rear master cylinder line which I admit may have been my fault since I let the side plate hang from it during some maintenance. Number three is the rear flex line between the ABS and the caliper. This is quite irritating since like my FD, the only reason it failed was sloppy assembly from the factory. The banjo fitting where it transitions to the hard line was 90 degrees up from where it should have been. This caused a 90 degree turn and subsequent stress point where the rubber was swagged onto the banjo. To explain it another way, the banjo fitting should have been pointed 45 degrees below level but instead was 45 degrees above level. Twenty thousand dollar plus motorcycle and they can't even bolt the brake lines up correctly! BMW did not get my business for the replacement part.
So if you still have your original lines, you may want to do a quick inspection with the bike on the center stand and see if this line is stressed on yours. It's a very simple fix which can save you a big headache later.
 

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deanwoolsey said:
So I lost my third brake line last night. Number one was the front master cylinder line which developed a pin-hole. Number two was the rear master cylinder line which I admit may have been my fault since I let the side plate hang from it during some maintenance. Number three is the rear flex line between the ABS and the caliper. This is quite irritating since like my FD, the only reason it failed was sloppy assembly from the factory. The banjo fitting where it transitions to the hard line was 90 degrees up from where it should have been. This caused a 90 degree turn and subsequent stress point where the rubber was swagged onto the banjo. To explain it another way, the banjo fitting should have been pointed 45 degrees below level but instead was 45 degrees above level. Twenty thousand dollar plus motorcycle and they can't even bolt the brake lines up correctly! BMW did not get my business for the replacement part.
So if you still have your original lines, you may want to do a quick inspection with the bike on the center stand and see if this line is stressed on yours. It's a very simple fix which can save you a big headache later.
Thanks, Dean. I will go and check mine tonight. I will definitely use Spiegler for my replacements. Glad to see you are back on the road. Would love to visit with you again.

Robert
 

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After my second line failed I just bit the bullet and bought Spieglers assuming that the remaining lines were on their way out. The BMW lines are nowhere near as quality as the Spieglers, plus the feel from the speiglers are much better.
 

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OK Dean, I checked mine and it looks fine. I was going to say something politically incorrect about the ethnicity of the assembly crew but thought better of it. Maybe a Monday assembly on yours was the problem.

Robert
 

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Discussion Starter #5
Here's a couple of photos of the new line which was custom built to my specs at the local hydraulic shop and tested to 3000 PSI. Note the lack of stress where the rubber exits the banjo collar. I reused the old sleeve and grommets so parts of it look old in the photo. You would have thought the mother-land could have done as well. $33.80 tax included.

Robert, give me a shout anytime you are going to be close by. Next time I'll set aside more time (and beer).
 

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expansionary said:
would have thought the mother-land could have done as well. $33.80 tax included.

Robert, give me a shout anytime you are going to be close by. Next time I'll set aside more time (and beer).
most likely just used an existing off the shelf part, did not design a new part, not unussual
 

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Discussion Starter #8 (Edited)
The wire going to the fill plug is the power for the chip detector which is what resides in that hole. Here's a link to that thread.

http://www.bmwlt.com/forums/showthread.php?t=43720&highlight=final+warning

The replacement brake line was custom fabbed. The company is in Australia and markets their products here to hydraulic shops.

http://www.brakequip.com.au/

The replacement is almost identical to the original part. The only difference is in the top connection where I specified the correct angle for the banjo. It is quite a bit different that the OE part, which is what caused the failure in my opinion. I regret not taking photos of the original when it was still in place.
 

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gary45 said:
most likely just used an existing off the shelf part, did not design a new part, not unussual
BMW averaged about 4K LTs a year, parts like brake lines are most likely off the shelf parts for other vehicles they manufacture and not engineered specifically for the LT
 

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Discussion Starter #10
Yes, I didn't quite catch what you meant the first time. I suppose that's possible, especially considering the poor alignment of the banjo fitting and hose on the original. It looked to me like the banjo was actually bent left when it should have been bent to the right.
 
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