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HARLEY DAVIDSON CHROME MASTER CYLINDER AND CLUTCH BRACKET KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-03-2011

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MASTER CYLINDER REMOVAL See Figure 1. Master cylinders designed for dual disc (two caliper) operation have an 11/16 inch (17.5 mm) bore, while those that are designed for single disc (one caliper) operation have a 9/16 inch (14.3 mm) bore. The bore size is stamped (1) on the master cylinder assembly inboard of the handlebar clamp bracket. NOTE Do not use an 9/16 inch bore master cylinder assembly on dual disc (two caliper) models or dual disc 11/16 inch bore master cylinder assembly on single disc (one caliper) models. These master cylinder assemblies are not interchangeable. Using the wrong assembly can adversely affect braking efficiency or result in brake failure which could result in death or serious injury. D.O.T. 4 brake fluid will damage painted and body panel surfaces it comes in contact with. Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) 1 is 01230 1. Bore stamp size location Figure 1. Verify Correct Master Cylinder Bore Size 1. Open bleeder nipple caps on front brake caliper. Install end of a length of clear plastic tubing over caliper bleeder valves, while placing free end in a suitable container. Open bleeder valves about 1/2-turn. Pump brake hand lever to drain brake fluid. Close bleeder valve. Avoid leakage. Be sure gaskets, banjo bolt(s), brake line and master cylinder bore are clean and undamaged before assembly. (00322a) 2. Remove bolt and two steel/rubber washers to disconnect fitting of hydraulic brake line from master cylinder. Discard washers. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 3. See Figure 2. Place the cardboard insert between the brake lever and lever bracket

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2007 Yamaha R1 Front Brake Line Kit Installation instructions

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Filed Under (Yamaha) by admin on 27-01-2011

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To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process can be messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. Take note of how the stock system was routed in case you need to re-install it. Step 4: Install the right and left (to your right and left as you sit on the bike) lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Double banjo hex, washer, 40-degree banjo labeled for right line, washer, 20-degree banjo labeled for left line, washer, master cylinder. Double banjo bolts must be torqued at 12 FT pounds. (See picture A for sequence) Step 5: Route brake lines below the stock lower triple clamp, and zip tie them together. This will ensure your lines stay in position as the steering moves. Also, make sure the lines are secured beneath the steering stabilizer rod. (See picture C) Step 6: Before installing the lines onto the right and left calipers, replace the OEM bracket with the enclosed “C-clip”. Route the hose through the new bracket and thread the single banjo bolts at each caliper using the following sequence: 20-degree banjo, washer, single banjo bolt, washer, thread into caliper. Torque banjo bolts to 12 FT pounds. (See picture B) Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Step 7: Bleed brake system according to owner’s manual, and build appropriate pressure. Keep in mind your master cylinder is equipped with it’s own bleeder nipple. Finish with Galfer DOT-4 brake fluid

2008 Kawasaki ZG1400 Concours ABS Front 3-Line Kit and FK003D625R Single Line Rear INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 29-01-2011

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Step 1: Identify the key components that complete our front brake line kit: You should have three (3) hoses, one (1) double banjo bolt, and two (2) single banjo bolts There are also a total of nine (9) washers and (3) brass conic inversors. Seven (7) washers and two (2) inversors will be used; the rest are spares. If you have purchased a rear kit as well, locate the following additional pieces: One (1) hose with bracket and c-clip attached, one (1) single banjo bolt, two (2) brass inversors and three (3) washers. You will use one (1) “olive” conic inversor and two (2) washers, the rest are spares. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process can be messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. On the front brake line kit, we are replacing three hoses and their respective blocks (see pictures 1-2 for blocks) . For the rear, we are replacing one hose from the master cylinder to the ABS hard line. Take note of how the stock system was routed, in case you need to reinstall it. Step 4: Locate Line A – This will travel from the master cylinder to the ABS Junction. (See picture 3) You will use a single banjo bolt and two washers at the master cylinder, and an “olive” inversor to thread female end to hard pipe for incoming ABS (right side). * We have replaced the block at the upper triple clamp with a c-clip; please use your stock bolt to thread this in. (See picture 4) Locate Line B – This will travel from the ABS Junction to the right caliper. First, thread the female end to the hard pipe for outgoing ABS (left side). There will be a bolt from the OEM blocks at ABS Junction; please use this to thread c-clips into frame as shown in picture 5 . There is another bolt/OEM block located at the lower triple clamp; please use this to thread the c-clip in as seen in picture 6. Locate Line C – This will cross over the front fender using OEM holders, from right caliper to left caliper. Thread caliper banjos from Line B and C using the following sequence: double banjo hex, washer, 40- degree banjo from Line C, washer, 20-degree banjo from Line B, washer, caliper. Please see pictures 7 and 8 for reference. Thread single banjo bolt into left caliper, using two washers and 40-degree banjo. If applicable, locate rear Line D – this will travel from the rear master cylinder to the hard line for ABS. Thread the hard pipe into female end using a “olive” inversor, and attach bracket to swingarm as seen in picture 9 . Use the bolt from the holder for ABS hose, and sit our bracket on top of the OEM holder. Using the bolt from the OEM ABS hose holder in location shown in picture 10 , attach the c-clip on top of holder and tighten. Finally, thread 30-degree banjo in caliper using the following sequence: single banjo hex, washer, banjo, washer, caliper

2006 2007 Yamaha R6 Front Brake Line Kit INSTALLATION

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Filed Under (Yamaha) by admin on 25-05-2011

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Identify the key components that complete our brake line kit: You should have two (2) hoses, one (1) double banjo bolt, two (2) single banjo bolts, and one (1) zip ties. There are also a total of nine (9) washers. Seven (7) will be used, and two (2) are spares. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process can be messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. Take note of how the stock system was routed in case you need to re-install it. Please note there is a plastic shield on the lower triple clamp of most models; we took this piece off to ease installation. Step 4: Install the right and left (to your right and left as you sit on the bike) lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Double banjo hex, washer, 40-degree banjo labeled for right line, washer, 20-degree banjo labeled for left line, washer, master cylinder. Please see picture A for reference! Double banjo bolts must be torqued at 12 FT pounds.

2008 SUZUKI GSXR1300 Hayabusa Front Brake Line Kit INSTALLATION INSTRUCTIONS

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Filed Under (Suzuki) by admin on 09-01-2011

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Step 1: Identify the key components that complete our brake line kit: You should have two (2) hoses, one (1) double banjo bolt, and two (2) single banjo bolts. There are also a total of nine (9) washers. Seven (7) will be used, and two (2) are spares. We strongly suggest having a professional mechanic install these brake lines, and all other installations void warranty. Step 2: To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip! Step 3: After drying out the OEM brake system, uninstall stock hoses. Take note of how the stock system was routed in case you need to re-install it. Please note there is a plastic shield on the lower triple clamp of your machine; we took this piece off to ease installation. Remove the OEM hose holder, and keep the bolt for later use. (See picture C) Step 4: Install the right and left (to your right and left as you sit on the bike) lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Double banjo hex, washer, straight banjo labeled for right line, washer, 12-degree banjo labeled for left line, washer, master cylinder. Please see picture A for reference! Double banjo bolts must be torqued at 12 FT pounds. Step 5: Route both brake lines through the enclosed c-clip, and attach to the lower triple clamp using the bolt from the OEM holder. (See picture B) Drop the lines down and thread the single banjo bolts at each caliper using the following sequence: single banjo hex, washer, 20-degree banjo, washer, thread into caliper. Torque banjo bolts to 12 FT pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions

2004-2007 HONDA CBR 1000RR Super bike Kit INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 29-01-2011

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To ensure no paint damage from a brake fluid spill, completely cover the front end of the bike. This process is messy, and brake fluid WILL drip! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Make sure to save the nut and bolt that are currently holding the stock lower section of the hoses. (See picture A) Step 4: Install the Galfer adapters onto the right and left calipers. Thread each adapter into the calipers with one washer, and torque at 12 to 13 ft pounds. Step 5: Install the right and left lines to the calipers, using the shorter line on the right side. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, 40-degree banjo from right line, washer, 40-degree banjo from left line, washer, and double banjo hex. Double banjo bolt torque level is 12 FT Pounds. (For positioning see picture B) . Make sure that the 90-degree fittings on each caliper are pointing straight up (see picture C) . Thread each banjo end onto the adapter, and torque to 6 ½ Ft pounds. Please tighten the “C” clips on the fender using the OEM bolts we asked you to save above. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and clear from any obstructions. Once the lines have been checked for clearance, using the galfer 2line clip to bring the lines together and mounting it to the triple tree will insure proper clearness and routing. (See picture D) Step 6: Bleed brake system according to owner’s manual, and build appropriate pressure. Finishing with Galfer DOT 4- brake fluid is recommended.

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2007-2008 KAWASAKI ZX-6RR GP Kit INSTALLATION INSTRUCTIONS

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Filed Under (Kawasaki) by admin on 05-01-2011

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Step 1: Identify the key components that complete our GP kit: You should have 3-line (front kit) , 3 SINGLE banjo bolt and 1 C-CLIP. There are also a total of 8 washers. 6 will be used, and 2 are spares. We strongly suggest having a professional mechanic install these brake lines, all other installations will VOID the warranty . Inspect your brake system after every race. Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install the GALFER GP 3-Line starting with the master cylinder line (top line). Torque level is 12 to 13 ft pounds. (See picture A2) Step 5: Install the C-CLIP provided to the lower triple tee left line needs to be held by c-clip [see picture A4] . Lower lines will travel in front of the forks to the calipers; three single banjo bolt (see picture A1) are included for master cylinder to each caliper. The positioning sequence on the master cylinder is as follows: Master cylinder, washer, 40-degree banjo (Top line), and washer. Single banjo bolt torque level is 12 FT Pounds. ( See picture A2 for positioning) Make sure that the [ CALIPER fittings ] on each caliper are positioned [ positioning ] (see picture A5- A6) . Thread banjo bolt into the caliper, and torque bolt to 12 to 13 Ft pounds. Before you proceed to the next step, please check for clearance of the lines. Compress the front end to make sure that the lines are not binding with anything. When the front end is fully extended or fully compressed, double check that the lines are traveling correctly and are clear of any obstructions. Once the lines have been checked for clearance.

HARLEY DAVIDSON CHROME FRONT BRAKE MASTER CYLINDER KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 25-11-2010

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1. See Figure 2. Drain the brake fluid. a. Open bleeder nipple cap on front brake caliper. b. Install end of a length of clear plastic tubing over caliper bleeder valve, while placing free end in a suitable container. c. Open bleeder valve about 1/2-turn. d. Pump brake hand lever to drain brake fluid. e. Remove cover. f. Close bleeder valve. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 2. Remove bolt and 2 steel/rubber washers to disconnect fitting of hydraulic brake line from master cylinder. Discard washers. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) is 01010 Figure 3. 5/32 in. (4 mm) Cardboard Insert 3. See Figure 3. Place the cardboard insert between the brake lever and lever bracket. 4. Using T27 TORX® drive head, remove the 2 screws with flat washers securing the handlebar clamp to the master cylinder housing. Remove the brake lever/master cylinder assembly and clamp from the handlebar. Wear safety glasses or goggles when removing or installing retaining rings. Retaining rings can slip from the pliers and could be propelled with enough force to cause serious eye injury. (00312a) 5. Remove retaining ring from pivot pin groove at bottom of master cylinder bracket. 6. Remove pivot pin and brake hand lever from master cylinder assembly. NOTE New master cylinder comes with all internal components preassembled. It is not necessary to remove the components from the bore of the old master cylinder. See Figure 9. Use denatured alcohol to clean clutch system components. Do not use mineral-based solvents (such as gasoline or paint thinner), which will deteriorate rubber parts even after assembly. Deterioration of these components can cause clutch failure, which could result in death or serious injury. (00296a) 7. With denatured alcohol, clean and inspect all parts that will be reused. Replace as necessary and wipe dry with a clean lint free cloth

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2005 HONDA CBR 600RR Superbike BRAKE LINES INSTALLATION INSTRUCTIONS

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Filed Under (Honda) by admin on 03-01-2011

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Step 1: Identify the key components that complete our Super bike KIT, you should have 2 lines (front Kit), and 1 Double banjo bolt and 2 lower adapters. There are also a total of 7 washers, 5 will be used, and 2 are spares. We ALWAYS strongly suggest having a professional mechanic install these brake lines, all other installations VOID warranty. Inspect your brake system after every race. Step 2: Cover the complete front end of the bike so that if any brake fluid does spill the paint will not be damaged, brake fluid will spill, there is no question!! Step 3: Uninstall stock hoses; be aware of how the stock system was routed in case you need to re-install it. Step 4: Install onto the calipers the Galfer adapter, the course thread area threads to the caliper with one washer. Torque level is 12 to 13 ft pounds. (See picture on adapter A) Step 5: Install right and left lines to the master cylinder, the right line is the shortest out of the two lines. These lines will travel from the master cylinder to the calipers; a double banjo bolt is included to run two lines down. (Picture B). This is the sequence on the master cylinder: Master cylinder, washer, straight banjo (from right line), washer, 12 degree banjo (from left line) washer and double banjo hex. Double banjo bolt torque level is 12 FT Pounds . (For positioning see picture G). Banjo 12 on left line must be facing a bit more to the left than the straight banjo of right line, so that the lines can cross at lower triple clamp better. On the calipers, make sure that the 90-degree fittings are pointing out a little bit, thread banjo end to the adapter, torque the end to 6 ½ Ft pounds . (See pictures C, D, E) Before you begin bleeding process, please check for clearance of the lines, push on the front end down, see that the lines are not binding with anything and that when the front end is fully extended or fully under pressure the lines are traveling correctly and clear from any obstructions. Ones the lines have been check for clearance; the two lines are Zip tied together at the same level of the lower triple clamp area. (See pictures F), please make sure that lines cross each other. Step 6: Bleed system, conventional bleeding, pump and release the air from caliper bleed nipples… DOT 4-brake fluid is recommended.

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HARLEY-DAVIDSON Starter Relay Location Guide

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Filed Under (Harley Davidson) by admin on 18-04-2012

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Touring 1998 – 2007 Additional Notes: Relay Location: Under Seat in rubber Boot Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 ***2004 – 2007 FLHR series bikes & 2007 FLHX require additional Adaptor AD-1 & DGD-1. Start Relay is in Power Distribution box. Replaces H-D Relay part# 31579-04 Softails 2000 – 2007 Additional Notes: 2000 is when the Softails changed to Twin Cams. Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Softails 1996 – 1999 Additional Notes: Relay Location: Under Seat in covered Power Distribution Box. Battery Connection: Under Seat,Visiable Installation Notes: No Access Issues Factory Relay Type: FULL SIZE Factory Relay Part #: 31504-91A Connection Type: Ground Lug to Battery + Terminial System Relay Replacement: R-S-1 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05
Dyna 2007 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Replace Batt 15A Fuse with Supplied Fuse Holder Installation Notes: No Access Issues Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Tap 12v Fuse (Batt 15A) System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Dyna 2000 – 2005 Additional Notes: Relay Location: Under Side Panel Cover. Battery Connection: Battery connection is made direct to Battery Buss to right of Relay * see Pic3 Installation Notes: Remove Outer Cover, then Remove 4 bolts holding secondary protector plate in place. Relay is on the upper left. Factory Relay Type: 1/2 SIZE Factory Relay Part #: 31522-00B Connection Type: Ground Lug to Battery Buss + Terminial System Relay Replacement: R-S-3 Circuit: Cold C Copywrite 2005 Identity Inv. LLC As of: 11.05 Pic3 Sportster 2004-2007

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