So today I had some time since I’m working at home and waiting for Travis to come by so we can exchange some goodies (controller, contactor, batteries, charger, latest xenoDisplay build, etc. etc.).  I decided to install the new brake lines I bought.

Since the SPARC XEV uses a Ninja 250 for various donor parts (rear shock, swing arm, wheels, tires, brakes, etc.) I decided to save some money for the initial version by using motorcycle style handlebars and motorcycle hand controls (specifically, hand brake levers, twist grip throttle, etc.) since I had those parts available and paid for (from the original electric motorcycle conversion project).

As you can see, the lines installed just fine with no problems.

The brake lines go from the brake lever main cylinder to a Y-adapter which splits the line into left and right (one line per wheel – one disc per wheel).  While there is a little awkwardness to fitting the Y-adapter (I should have gotten a few straight banjo fittings instead of all 35 degree angle fittings), it all went together decently without much hassle.

So there I was, thinking that it was smooth sailing from then on.  All I had to do was flush and fill the system with new brake fluid, bleed the system, and I’d be ready to do some brake testing.

Alas, all was not smooth sailing.   Along comes a little surprise – the bolt screws holding the brake reservoir cap on are stuck (rusted? gummed?) and trying to unscrew them with a Phillips screwdriver gets me nothing but stripped screw caps… argh.

Brake reservoir with stripped screws

So, for now, I’m at an impasse.  I’ll have to figure out how I can get those screws out without damaging the rest of the reservoir.  I’m not sure how I’ll do that just yet.   In fact, I’m wondering if I should just dump the hand brake lever and go with a foot pedal but we’ll see.

Eric