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Discussion Starter #1
Ok. Today I went to give my 9 year old daughter a ride around the block. Helmets on and away we go. Well it just quit at a stop sign. Nice. I smell fuel. It won't start again and I'm dripping fuel. I expect this from my 1987 FJ1200, but not this bike. I read the forums and find I'm not the only one. Ok, I rode real hard over the weekend on some very curvy roads and no problem in 110 miles. Now this bike has just over 2000 miles on it and I've been riding it about 30 miles a day. It's a fun bike, but how can I trust that kind of behavior? Anyway, I'm a competent mechanic (and mechanical engineer) but I don't want to always be working on this thing. Anyone have any comforting words about Brutale reliability? Thanks.

Ps. Siphoned the tank and will pull it tomorrow and check rubber components including fuel lines, vacuum tube seals etc.
 

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Reckon you'll find it's the plastic quick connect fuel connectors between the fuel lines and the tank. For some unknown reason they skimped out and fitted $5 plastic connectors instead of $20 metal ones. I had my bike run like rubbish due to one of these failing.

Look up CAG here or on ebay, and get some of these straight up and you'll never have to worry about them again.

Overall, I'll admit I've spent a fair bit of time and money on the Brutale. But these are the known issues with these bikes and I'd probably would've changed this stuff over regardless of the age of the bike. This includes:
*Fuel line connector fittings (plastic to metal)
*Rear hub (I replaced with a more bullet proof version, but apparently you can either overhaul with better bearings, or simply keep an eye on the lube and all is well)
*Front bearings (for me it was worth swapping over while I did the rear so I knew they were both going to cover the same number of miles)
*Performance filters
*Full exhaust system

Unfortunately, like the fuel fittings, the bike is designed really well, with a few things overlooked in the materials department, and I can only imagine it was in the chase to reduce costs.

The only other thing I did was add the PC3 to help with the fueling because the exhaust breathes differently to the standard one.

Personally, I'm happy with the mods, and confident with the rest of the bike performing as desired.
 

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Interior vent hoses are known to deteriorate over time and split...the crappy ethanol gas we get doesn't help!!!

Miles are meaningless...it is all about time. Easy to fix and be sure to get some quality submersible rubber hoses when you replace them...also make them about 6~10 inches longer so it easier to work on the pump or replace the fuel filter in the future.
 

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Discussion Starter #4
Thanks to both of you for your thoughts. I'll get the metal fittings and check rubber condition while I've got it apart. I plan on dealing with both front and rear bearings this winter.
 
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