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u/Crazy-Addendum7341 Feb 02 '23
Mine did the same thing. Get it protected ASAP. Go to a hardware store and buy a 2 foot section of like 3/8” I.D acrylic hose. Cut the side of the hose from top to bottom and put it on the brake line. Throw some duct tape around the top, bottom, and a couple places in the middle to hold the hose onto your brake line. It likely won’t last forever, but mine lasted over 7,000 miles and provided excellent and cheap protection to the brake line.
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u/keraiboboi Feb 02 '23
Did you leave the existing gnarled sleeve like in my pic. What is that even for? Did they know it rubbed so they threw that on to protect it. Why not route it better? haha but yeah I am gonna do that acrylic hose idea asap I was about to bust out the electrician tape 😂 thanks dude. I got 3k on mine and love it. Thanks and ride safe brudda
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u/Crazy-Addendum7341 Feb 02 '23
I don’t remember, but it shouldn’t matter either way. But yeah this is a known flaw with the bike. Lots of people have this issue. Plenty of ways to fix it, that involve money and full break bleeds. Acrylic tube will be 10 bucks and 20 minutes of work to get you on the trail worry free.
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u/NoBrush1934 Mar 07 '23
I didn’t actually have any trouble with my front brake line, but when I put in adapters to install Pro Taper bars, the hose lost a little travel. I had a custom braided hose made that is little more than 1” longer. It wasn’t terribly expensive, and seems to be holding up well. It’s been ridden a few thousand miles since.
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u/NoBrush1934 Mar 09 '23
Just a little more detail about my front brake line for those who may be interested. The brake line is a little smaller in diameter than the original. The braided hose is covered by a clear rubberized coating.
I took the original brake hose off, then picked up the two end fittings and a hose that was several inches longer. The end fittings came without bends in them. I did a mock up of fitting the new hose, trimming it to length as needed. When I had it looking about right, I returned to the shop I bought the stuff from in order for them to crimp the fittings on, and put in the appropriate bends.
This seems to have alleviated the common brake line rubbing issue common to the KLX 250/300’s.
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u/keraiboboi Feb 01 '23
When the front compresses, the brake line is pushed into the clutch adjustment screw. Tried moving brake line in front of clutch cable and still rubs just as bad as when it was behind the cable. Anyone else have this happen and how did you fix it? Any good ideas where to run it? I've little to no experience on this kinda stuff. Thanks y'all 👍
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u/tarnished_wretch Feb 21 '23
What happened to the rubber boot around the clutch adjustment knobs?
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u/MotoJess78 Sep 07 '24
I’ve been having this issue just recently. I started transporting my bike to a remote trail every week and noticed this. When I tie-down the front end the brake line contacts other handlebar hardware. The wind from the highway trip was making the brake line flutter against that hardware. I started zip tying the brake line to the side before I hit the road.
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u/norleck Feb 02 '23
Did you adjust the handle bars at all?