Tenere 700: HEL Performance Stainless Braided 7 line Brake Kit #HBK9027 + Brake Bleeding Instructions, Mityvac MV8500 Vacuum/Pressure Pump, ATE Typ 200 Dot 4 Brake Fluid + Galfer FD165G1054 Semi-Metalic Carbon Rear Pads + OEM Yamaha Rear Rotor

 HEL Performance Stainless Braided 7 line Brake Kit #HBK9027 for 2019-24 Yamaha Tenere 700 

Product information can be viewed on the HEL website via this link.

Pic from HEL Website 

The high quality HEL brake line kit is made to order (selectable coloured PVC coating bonded to the stainless steel braided line), comes with pre-assembled lengths matching the oem lines & angle of fittings (the banjo fittings can also be rotated to ensure optimal fitment - see pic below), stanless steel fittings/banjo bolts + copper crush washers & utilizes the oem metal lines (ABS pump to front of radiator & 2 lines from above the motor to behind the rear shock) via compression fittings...the only oem rubber brake line not replaced is the low pressure gravity-fed hose from the rear reservoir to the rear master cylinder. Purchased from local Vancouver retailer Bushpigs Performance during Black Friday pricing last year (thanks Alex 😀).

Pic from HEL Website 

HEL Performance Brake Line Kit Instruction Pamphlet

Installation is relatively straight forward, however, there are a few nitpicks:

• the individual lines are not labelled, so care must be taken to match to the correct oem line

• as with most aftermarket brake lines, the HEL kit does not have the locating tabs on the banjo fittings making it more difficult to prevent rotation while torquing the banjo bolts to 22 lb ft or 30 Nm

• The supplied stainless steel HEL banjo bolts are shorter than the oem bolts (18mm vs 20 mm, not sure if it translates to a quantifiable reduction in bolt/thread strength/integrity, but deviates from that specified by Yamaha) except for the longer double banjo bolt for the right front caliper to accomodate the additional cross over line to the left caliper, which is the same length as the oem bolt (30 mm)

• the smaller diameter braided HEL brake line kit does NOT come with a full complement of mounting grommets to fit the various types/sizes of oem straps/mounting brackets used to secure the lines & attach other wires to the brake lines (i.e. the front wheel brake lines incorporate 4 pre-formed plastic straps to secure the ABS sensor wiring harness to the brake lines). TIP: Cut off & reuse the oem rubber grommets where needed & cut off a length of oem thin rubber sheathing to wrap the HEL smaller diameter lines for use with the smaller pre-formed plastic straps attaching other wires to the brake lines. 

HEL Performance Stainless Braided Brake Line Kit #HBK9027 for 2019-24 Yamaha Tenere 700

HEL Kit #HBK9027 Deficiencies (attn HEL): 

NOTE: The 1st 3 issues below were actual defects in the kit supplied by HEL, the remaining items + those noted above as 'nitpicks' are suggested enhancements that would elevate the kit to a comprehensive & complete bolt on upgrade, incorporating all oem mounts & design integrity as specified by Yamaha. 

Most of these issues were easily rectified by reusing eom parts, but did not anticipate having to do this for what was perceived as a premium product upgrade. 

The kit does include a 2 page generic instruction pamphlet for instalation, priming (filling) the system, bleeding the system, troubleshooting & final checks (see pics above), but none of HEL's nonclamenture references reusing any oem components. 

• missing 1 short (18 mm) stainless steel banjo bolt (6 vs 7 short + 1 long (30 mm) = 7 vs 8 total) - had to reuse an oem banjo bolt

• 1 mounting grommet was missing (2 vs 3) on the brake line connecting from the oem metal line in front of the top of the radiator going to the right front caliper (compare pic above of my kit to pic from the HEL website at the beginning of this blog post)

• the HEL plastic female compression fitting housing mounting bolt hole for the line from the rear master cylinder to the oem metal line required drilling larger to fit over the mounting bolt (see pic above)

• the front caliper cross over line should have 2 mounting grommets to match the 2 oem mounts located on either side of the fender (none are provided - see pic above)

• the front master cylinder line to the ABS pump should have 1 more (total of 2) mounting grommet to match the 2 oem mounts (1 located at the base of the head stock & 1 located adjacent to the ignition - see pic above & pics further below labelled 'HEL line from Front Master Cylinder to ABS Pump')

• The u-shaped metal clamp/mount attaching to the underside of the lower triple clamp uses an oem rubber grommet flat on one side & round on the remaining surface (see pic below) that is NOT included in the HEL kit...requiring cutting it off the oem line & reusing it with the HEL line. This grommet & associated mount is critical to eliminating metal to braided line contact/chafing & providing a stabilized mount for the 180 degree narrow arc bend & tensioned braided line that would see constant flex/movement from the long travel suspension is a curious omission for a premium product with an intended long service life.

Removal of Tank, Side Panels & Air Box is Neccessary for Installation

Step by step instructions for tank & side panel removal can be viewed via this link.

Step by step instructions for airbox removal can be viewed via this link.

ABS Pump Brake Line Orientation

NOTE: It is extremely important not to alter which line goes where -  the ABS pump is divided into front & back circuits, each with an incoming supply line from the respective master cylinder & outgoing line to the respective front & rear calipers. 

Orientation of OEM Metal Lines from Front to Back

NOTE: The oem metal lines cross over near the throttle bodies reversing the orientation of the left & right front connectors vs the rear connectors.

HEL Lines fitted to ABS pump & OEM metal brake lines to Rear Master Cylinder & Caliper

HEL lines to Front Calipers

NOTE: The u-shaped metal clamp/mount attaching to the underside of the lower triple clamp uses an oem rubber grommet flat on one side & round on the remaining surface (see pic below) that is NOT included in the HEL kit...requiring cutting it off the oem line & reusing it with the HEL line.

 

HEL line from Front Master Cylinder to ABS Pump

TIP: Cut off & reuse the oem rubber grommet for the plastic clamp adjacent to the ignition as it is NOT included in the HEL kit

HEL does provide a mounting grommet for the plastic clamp located at the base of the head stock

HEL rear caliper line

OEM Metal Lines Connecting to HEL Lines to Rear Master Cylinder & Caliper 

Comparison of HEL, Speigler & Galfer Braided Brake Line Kits for Tenere 700

Brake Bleeding Instructions, Mityvac MV8500 Vacuum/Pressure Pump, ATE Typ 200 Dot 4 Brake Fluid

Step by step instructions for bleeding the Tenere 700 brakes using a Mityvac MV8500 vacuum/pressure pump & ATE Typ 200 Dot 4 brake fluid can be viewed via this link. 

Galfer FD165G1054 Semi-Metalic Carbon Rear Pads + OEM Yamaha Rear Rotor

If the rear brake lever is adjusted downward beyond the safe effective range of the master cylinder it can cause the rear pads to self-activate because of fluid expansion resulting from heat not allowing the pads to fully disengage prematurally accelerating wear of  the pads & rotor. 

This is more of a problem with the original Camel 'The Fix' (v1) replacement rear brake lever because it does not incorporate as much bend as the eom lever...Camel subsequently added an eom bend version of 'The Fix' (v2) for use with lowered foot pegs. Unfortunately, this happened after I adjusted my brake lever a little lower last year for better operation with my lowered Pivot Pegz MK4 & toasted the pads & rotor.

Install new Galfer pads, detailed info can be viewed via this link & oem Yamaha rear rotor. 

Galfer FD165G1054 Semi-Metalic Carbon Rear Pads

OEM Yamaha Tenere 700 BW3-2582W-01 Rear Rotor

Aaron at Modern Motorcycles has very good pricing on parts ordered directly from Japan if you can time the purchase when he places a bulk order.