MOTORCYCLE BRAKE INFORMATION TO ORDER OR YOU NEED MORE INFO. PLEASE CONTACT US sales@h-e-lusa.com
Welcome to the HEL Performance Brake
Doctor. These pages are designed to give you an overview of the braking
system of your vehicle. Brake hydraulics are a complex subject and the
information contained within the force and pressure, friction and
piston travel pages can be quite technical and hard to understand.

BRAKE INFO - Introduction, Disclaimer and Basic Hydraulics
These pages are offered as an introduction to the
principles and parts of the braking system. Reading this guide will not
turn you into an expert overnight. We have made every attempt to be
accurate and easy to read but we cannot impart the gifts of skill,
experience and common sense. If after reading these pages you feel
inclined to carry out alterations to the braking system of a bike we
will not accept responsibility for what happens next. You are
responsible for your own actions and these pages have been placed
online to only offer an introduction into the braking system and to
hopefully give you a greater background into how things work, what
effects changes may have and what different parts of the system do. We
will obviously be happy to answer any questions you may have though

POWER
The most powerful part of your
motorcycle is not the engine - it's the brakes. That's a fact. Consider
this - A GSXR1000 can do a standing quarter mile in 10.8 seconds with a
terminal speed of 138mph. Yet the brakes can do the same amount of
work, but in reverse, in just 6.8 seconds...

HYDRULICS
The name hydraulics comes from the
Greek word 'hydro' meaning water and 'aulos' meaning pipe. The basics
of any hydraulic braking system are as follows. For a hydraulic system
to function it must be closed and completely full of fluid and leak
free – No fluid can be allowed to leave and no air can be allowed
to enter.
The name hydraulics comes from the Greek word 'hydro' meaning water and
'aulos' meaning pipe. The basics of any hydraulic braking system are as
follows. For a hydraulic system to function it must be closed and
completely full of fluid and leak free – No fluid can be allowed
to leave and no air can be allowed to enter.
In a closed, sealed hydraulic system as outlined above the following laws are true
Fluid cannot be compressed to a lesser volume, no matter how high the pressure
Pressure is equal over all surfaces of the containing system
The things that concern us most with brake hydraulics are the following :
Pressure -
Is a constant in the hydraulic system. If you put 10 psi into a system
hydraulic laws state that this 10 psi will act on all surfaces within
the system equally. Pressure In = Pressure Out.
Force -
A 1 sq inch master cylinder with 10 lb of force applied to it will
produce 10 lb of force per square inch or 10 psi. If the calipers have
a surface area of 10 square inches then the force here will be 10 x 10
lb which will mean the calipers produce 100 lb of force. The pressure
acting on the system is the same, in this case 10 psi, but the force
can be altered by changing the surface area of the calipers.
Fluid Displacement -
If our 1 sq inch master cylinder travels forward 1" then the amount of
fluid it displaces will be 1 cubic inch. If this fluid is then spread
over the 10 square inches of caliper the calipers will only be able to
move 1/10th of an inch. You will have huge force (100 lb) but the
caliper pistons may not move forward enough to grip the disc tightly
and so give a weaker brake. This can be seen to happen on some
motorcycles which have a small master cylinder piston and two pot
calipers. If the two pots are exchanged for six pot calipers then the
surface area increases and the force increases at the caliper BUT the
small master cylinder only moves a small amount of fluid which in turn
equates to a smaller movement of the caliper pistons.
Lever Pivot Point -
Any effort you apply with your hand should push the pads against the
disc. But your hand isn't that strong. To make the point grab hold of
something and squeeze it really hard - do you think that's enough
pressure to stop 270kgs of bike and rider from 180mph? Initially the
brake lever itself gives you an advantage by multiplying the force at
your hand through the lever. For instance, the distance from the lever
pivot point to the middle of the lever (where your fingers are) might
be 130mm. And yet the distance from the pivot point to the point where
the lever acts on the master cylinder might only be 20mm. So, roughly
speaking any force applied to the lever will be 6.5 times greater at
the master cylinder (130mm/20mm = 6.5)
QUESTION - Can you use any fluid in the braking system ?
No you cannot. The fluid in the braking system must be a designated
brake fluid which meets with certain specifications - DOT3, DOT4, DOT5
or DOT 5.1 are the most common and your owners manual will inform you
of the fluid used as standard in the system. Don't use aircraft
hydraulic fluid (even if you can get hold of it) - it isn't the brake
fluid equivalent of Avgas and do not use the mineral based fluid
formulated for Citroens either
QUESTION - What types of brake fluid are available ?
There are basically two types of fluid : glycol-based and
silicone-based. You can use one or the other but NEVER mix the two
fluids. If you want to use a different fluid than the one in your
system ( glycol to silicone / silicone to glycol) then you will need to
flush the system before changing. Brake fluid is available in different
specifications to meet American Department Of Transport (DOT)
requirements. These DOT regulations are occasionally updated but
basically the higher the DOT rating the higher quality, higher boiling
point and more expensive the fluid. DOT3 is the basic brake fluid. DOT
4 is a higher standard and both of these fluids absorb water - they are
hydroscopic but DOT4 fluid contains additives which prevent water
affecting the fluids performance to the same degree. DOT 5 was
originally formulated for silicone based brake fluid although there is
now a new DOT5.1 standard for glycol based fluid which has some of the
desirable properties of silicone fluids. Both types - glycol based and
silicone have different pros and cons though.
QUESTION - What are the boiling points of brake fluids ?
Brake fluid works in a harsh environment being close to the heat
generated by the braking system the fluid heats up and under extreme
conditions such as racing this can lead to the fluid boiling. This
manufacturers found that by increasing the boiling point the fluid
performed better in use as when fluid boils it leads to cavitation
within the system and loss of braking pressure. The boiling points are
as follows :
| Minimum
Specification |
Good Brand Min
Spec |
|
|
|
|
|
|
DRY |
WET |
DRY |
WET |
| DOT 3 |
205 Deg C |
140 Deg C |
220 Deg C |
150 Deg
C |
| DOT 4 |
230 Deg C |
155 Deg C |
260 Deg C |
170 Deg
C |
| DOT 5 |
260 Deg C |
180 Deg C |
270 Deg C |
190 Deg
C |
| DOT 5.1 |
260 Deg C |
180 Deg C |
270 Deg C |
190 Deg C |
Wet figures above show the drop in performance when the fluid has a
certain water content (less than 3%). For example when DOT 5.1 is contaminated
with 3% water (which is considered a lot) performs almost as well as basic DOT 3
in prime condition. The most important thing to do is regularly change your
fluid - we suggest every three months but manufacturers suggest at least once
every twelve months. After six months use a typical DOT 3 fluid may have had
it's boiling point lowered from 205 degree's C to about 165 degree's
C
QUESTION - What are the pros and cons of fluids
?
DOT 3 and DOT 4 are hydroscopic - they allow water to be absorbed into
the fluid. This means that when heated up a fluid with water in it will boil
more quickly (water boils at a lower temperature than brake fluid) which will
lead to cavitation. DOT 5 does not absorb water and will not strip paint work
but as the water is not absorbed it simply sinks to the bottom of the system
which is usually the caliper where operating temperatures are very high. Water
in the caliper is bad as it can cause corrosion within the caliper although
silicone fluids contain corrosion inhibitors and as water has a lower boiling
point than fluid (100 Degree's C) there is more chance of boiling under
relatively light braking. Glycol based fluids can strip paintwork where as
silicone based do not. Silicone fluids also have a very long life which is why
it is used in military vehicles which may be stored for years without use but be
expected to be ready for action at a moments notice.
QUESTION - Do -02 lines give more pressure than -03
lines ?
No - the fitting of the smaller
dash 2 hoses sold by some manufacturers makes NO difference to the pressure
produced at the caliper as is commonly believed. There are no substantial
benefits associated with the use of dash 2 hoses except that the manufacturer
can charge you more for them. The only way to increase pressure coming out of
the system is to increase the pressure going into the system. 500 psi in equals
500 psi out - Fluid cannot be compressed to a lesser volume, no matter
how high the pressure and Pressure is equal over all surfaces of the
containing system .
QUESTION - What
is the difference in performance between two
full length front lines and an over the mudguard line kit
?
Nothing except for the way the system looks. Both systems operate in
exactly the same way and give you the same performance. As the system is a
closed hydraulic system without air in it when the fluid moves at one end the
same movement takes place at the other end. Because they have different lengths
doesn't mean that the system will work slower at one end than the other. Imagine
pushing two sticks away from you which are both 6" long - the ends both move at
the same time. Now imagine pushing two sticks - one is 6" and the other is 36" -
the ends still both move at exactly the same time. So the over the mudguard
gives the same performance as the 2 full length - it's just which you
prefer.
QUESTION - What's better - three front lines using the oem
splitter, 2 full length fronts or 2 fronts with one over the mudguard
?
As we have said above the three systems give the same performance but the
three line front has an additional 2 possible leak points in the system, is
heavier and harder to bleed than 2 front lines. It is easier to fit though as
you follow the oem setup. Another thing to remember is do you race or use the
bike on track days ? If so go for the 2 full length front as in the UK one of
the ACU rules state that you are not allowed an over the mudguard system unless
it is an original system.
QUESTION - Friction
Friction is resistance to
sliding. Any two objects in contact with and trying to move relative to each
other have friction. This can be low or high depending on the types of surface
in contact. If two surfaces in contact are sliding, the friction produces heat.
In braking systems friction is used to produce heat.
The process of creating this
heat stops the motorcycle. The amount of friction between two surfaces depends
on the materials and their roughness.
The amount of friction is
described by a number called the coefficient of friction. This number is
obtained by Friction Force being divided by the Perpendicular Force. To make
matters more complicated the coefficient of friction has two different values.
It is higher when there is no sliding but as soon as the surfaces start to move
relative to each other the friction coefficient drops to a lower
number.
This is why it is harder to
start something sliding than it is to keep it sliding. After sliding starts it
is called dynamic coefficient of friction. The higher the number the higher the amount
of friction and the lower the number the lower the amount of
friction.

|