1983 KZ440 Brake Line

I have been replacing parts on this bike to bring it back to stock as much as is reasonable. I am now looking to replace the brake line. The bike has a single stock line that is held in place by a clamp mounted on a bracket between the forks on it now. Looking at the 1983 parts diagram, it shows a dual line system with a metal splitter mounted on the bracket. I have that setup sitting on my bench. I am looking for opinions on whether one system is better than the other or if it makes any difference.
Thanks

It's easy to build your own line from Earl's parts. Check my 750E rebuild thread for photos and information on how to assembly them.

Thanks I will take a look at that.I was planning on using new braided lines for sure. Jut wondered if going with two for an "original" look or one would make any difference.

I don't think it matters. With two lines I guess there's more chances for leaks, but I've never had a brake line leak. One possible problem with a single line is that a new brake line might be a smaller O.D. than the stock lines & then might not fit the brake line bracket correctly. But again, I don't think it matters. my motorcycle has the 2 lines w the brake joint there at the forks.

Thanks. I will go with the stock look and use the 2 line setup.

Just make sure you use two good-condition copper washers per attachment (one on either side of the banjo fitting). As long as you do that, you could have 14 separate brake lines and they won't leak.

I'm not entirely sure what the junction block on the forks is for. My initial thought was that they used it to split the brake pressure between an optional dual-disc front brake on certain trims, but to my knowledge they never offered a 440 with a dual-disc front option. Perhaps they use the same brake lines as on the KZ550 LTD which may have had a dual-disc front available. It could also be there to reduce friction and simplify safe mounting of the brake line through the triple clamp area, providing a rigid attachment point for securing the brake line to the frame. Regardless of the actual reason, I trust Kawasaki's engineers knew what they were doing and probably had a reason for the split, so it's probably best to leave it present.

By Grcko: Thanks. I will go with the stock look and use the 2 line setup.

Just curious. Are you sure stock was 2 lines? I have no idea, but sometimes it's kind of hard to figure it out using the diagrams.

For comparison. Only one brake line is listed for the 83 KZ650-CSR, so I'm pretty sure the H3 only came one & the 82 H2 may have as well, since there's a long line listed in the 81-82 master cylinder diagram. The 81 for sure had two Fr brake lines.

On some models the brake light switch was mounted on that splitter. If that is not the case, then I suspect you can easily run a single long line directly from the master cylinder to the caliper.

The '83 440 belt diagram shows the 2 lines with the splitter. Since this was stock, I am going to use this setup mainly for the stock looks. The only difference will be that the top hose may be shorter as I don't have the stock taller bars. I am going to get new braided lines for the system. I will probably install the setup this weekend, get the exact measurements and then order the new lines.

Yes, the drawing shows 2 lines, but the diagram covers the 81-83 models. Sometimes Kawasaki kind of uses drawings that aren't exactly correct for all models covered. There's a long line in the parts list & the Fr fork diagram for the D4/D5 shows the fork cover bracket that would be used w the longer line (since the bracket has the brake line guide). But again, I have no idea what your motorcycle would have had. maybe Kawasaki used both in 83, depending upon what part of the world.

Nice catch. I didn't notice the bracket in the FR fork diagram. I am willing to bet that the long line was for the models with the tall bars and the split lines were for the shorter bars or visa-versa. I will measure both of them tonight and report back.

So I measured the long one and it is about 43" long give or take. The split one overall is about 40" give or take. The 43" one is to long on my bike as it is with my short bars but the 440 D5 originally came with taller bars and I bet it fit them. So I guess my answer is I go with the single line but have it made to fit the bars I have on now.