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Filed Under () by admin on 23-05-2017

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8950 and 8960 Series High Performance Tire Changer Operation Manual

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Filed Under (Tips and Review) by admin on 23-11-2010

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GENERAL CAUTIONS A. DURING THE USE AND MAINTENANCE OF THE MACHINE IT IS MANDATORY TO COMPLY WITH ALL LAWS AND REGULATIONS FOR ACCIDENT PREVEN- TION. B. THE ELECTRICAL POWER SOURCE MUST HAVE A GROUND CABLE AND THE GROUND CABLE OF THE MACHINE MUST BE CONNECTED TO THE GROUND CABLE OF THE POWER SOURCE. C. BEFORE ANY MAINTENANCE OR REPAIRS ARE ACCOMPLISHED THE MACHINE MUST BE DISCONNECTED FROM THE AIR AND ELECTRICAL SUPPLY. D. NEVER WEAR TIES, CHAINS OR OTHER LOOSE ARTICLES WHEN USING, MAINTAINING OR REPAIRING THE MACHINE. LONG HAIR IS ALSO DANGEROUS AND SHOULD BE KEPT UNDER A HAT. THE USER MUST WEAR PROPER SAFETY ATTIRE – GLOVES, SAFETY SHOES AND GLASSES. 2.0 INSTALLATION Your new JBC 8950 or 8960 Series Tire Changer requires a simple installation procedure requiring only a few moments. Follow these instructions carefully to insure proper and safe operation. The Tire Changer is delivered mounted to a wooden skid. Remove tire changer from its mounts carefully, taking care to avoid any back strain. Place Changer where proper operation will be unobstructed to all sides. Install the machine in a covered and dry place. 2.0.1 Models with SRA attached (8955IN, 8965IN) Once placed in the desired location the tire changer must be bolted to the floor using only the rear two mounting holes. Mounting anchors are provided with those machines with a Safety Restraint Arm. Tire Changer must be anchored to concrete floor if equipped with a “Safety Restraint Arm” BUILDING ELECTRICAL INSTALLATION MUST BE MADE BY A LICENSED ELECTRICIAN. Check that the electrical specifications of the power source are the same of the machine. The machine uses 110v, 60 hz, single phase 20 amp source. Electric specifications are clearly marked on a label at the rear of the machine. FAILURE TO PROVIDE PROPER ELECTRICAL SUPPLY AND GROUNDING WILL CREATE A SHOCK HAZARD TO THE OPERATOR

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Aermacchi IHRO1 Machine Specifications

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Filed Under (Aermacchi) by admin on 13-11-2010

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1. IHRO 1 caters for single cylinder thoroughbred Grand Prix racing motorcycles constructed during the period 1945-1972 inclusive, for the specific purpose of participation in Grand Prix competition during that era. Maximum capacity for any machine is 500cc, and wherever possible it is intended to run three classes, for machines up to 250cc, 350cc and 500cc. 2. Motorcycles must be presented in original, period condition, with no external updating. Period appearance seats, fuel tanks and fairings (if fitted) must be used. No external changes may be made to the appearance of any machine unless it can be proved that such a change was made in the period. Modern safety fixtures required by some federations and modifications mentioned in this document are not covered by this ruling. 3. No disc brakes are allowed. Drum brakes only may be used. 4. No alloy/magnesium wheels are allowed. Wire wheels only may be used. 5. All machines must have twin shock rear suspension: No monoshocks except Vincent Grey Flash. Suspension units must resemble period components, i.e. no external gas reservoirs etc. 6. All frames and swinging arms must conform exactly to period appearance; no box section swinging arms allowed unless fitted by the manufacturer to that machine in the period. 7. The maximum permitted rim width on either wheel is WM3. 8. No slick tyres, hand cut slicks or modern racing tyres designated by the manufacturer as being exclusively for wet weather use are permitted. Only the following rear tyres may be fitted. Any 19″ tyre. The following 18″ tyres, Dunlop 3.50×18, 3.50/3.25×18 KR124 and KR124A, Avon AM22 110/80×18 Rear Fitment and Avon AM18 120×18 9. Choice of carburettor is free, provided that this is of a period type cylindrical slide model, albeit of a later manufacture. Flat slide instruments are not permitted with the exception of Gardner carburettors. Fuel injection is not permitted except if it can be proved that particular motorcycle ran between 1945-72 with the same type of injection system fitted. A Wal Philips injector is classified under this heading. 10. The type of fuel used must conform to the ACU and FIM’s current fuel regulations for 100LL Avgas at 102 MON. See full specifications below. All machines must finish a race with a minimum of 2 litres of fuel in the tank to allow a sample to be taken for analysis. 11. The use of belt primary drives is encouraged.

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HARLEY DAVIDSON XL BRAIDED FRONT BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 30-03-2011

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REMOVAL Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) 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. Drain the brake fluid following the instructions in the service manual. Dispose of waste properly. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 2. Disconnect the battery, negative (-) cable first or remove the main fuse. Follow the instructions in the service manual 3. Remove bolt and two sealing washers to disconnect brake line fitting from master cylinder. Discard sealing washers, but save bolt for installation. 4. Remove bolt and two sealing washers to disconnect brake line fitting from front brake caliper. Discard sealing washers, but save bolt for installation. 5. Carefully make note of brake line routing, then remove existing brake line. NOTE This kit contains clamps and cable straps to either replace the original equipment clamps and cable straps being removed or to add additional brake line support. INSTALLATION Install proper length brake lines. Incorrect brake line length can adversely affect motorcycle operation, which could cause loss of control resulting in death or serious injury. (00325a) Replace brake line gaskets. Re-using original gaskets can cause brake failure and loss of vehicle control, which could result in death or serious injury. (00318a) Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 1. Position new sealing washers from kit on each side of hydraulic brake fittings (banjo fittings). Small ID washers are for caliper end, large ID washers are for master cylinder end. 2. Insert bolts (removed earlier) through washers and fittings. 3. Hold new braided brake line in position and install bolts into master cylinder and caliper. Tighten only enough to keep banjo fitting in the same orientation as the stock banjo fitting. 4. Verify there is no twist in the brake line. Adjust brake line if necessary. 5. Install clamps from kit by wrapping clamp around braided brake line at each of the clamp mounting locations. Verify clamps are oriented the same as the stock clamps. Install clamp screws but do not tighten. 6. Check entire length of braided brake line: a. Be sure brake line is not twisted. b. Turn handlebars fully-left and right while checking to make sure brake line does not contact any vehicle components. c. Be sure brake line length between clamps is sufficient. 7. Adjust brake line if necessary. 8. Tighten caliper and master cylinder banjo bolts to 20-25 ft-lbs (27-34 Nm) .

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HARLEY DAVIDSON ROAD KING FAT HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 11-03-2011

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PREPARATION – ALL MODELS To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) D.O.T. 4 brake fluid will dama ge painted and bod y 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) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled D.O.T. 4 brake fluid. 2. See the service manual and drain the brake fluid from the front brake reservoir. ORIGINAL HANDLEBAR REMOVAL NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 1. Using a T-40 TORX® drive head, remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. 2. Carefully make note of the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See FRONT BRAKE MASTER CYLINDER in the service manual. 3. Remove the old brake lines from the motorcycle. 4. Using a T27 TORX drive head, remove the front-brake master cylinder and clutch-lever assemblies (refer to CLUTCH CABLE in the service manual) from the stock handlebar.

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HARLEY DAVIDSON STREET SLAMMER HANDLEBAR KIT REMOVAL AND INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 15-02-2011

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This kit does not fit models equipped with Hydraulic Clutch Kits, handlebar mounted gauges or the Road Tech® Radio or FLHRS models equipped with an accessory windshield. REMOVAL Preparation – All Models To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect battery cables (negative (-) cable first) before proceeding. (00307a) Disconnect negative (-) battery cable first. If positive (+) cable should contact ground with negative (-) cable connected, the resulting sparks can cause a battery explosion, which could result in death or serious injury. (00049a) 1. See the service manual and remove the seat and disconnect battery cables or remove the main fuse. Save the seat hardware for installation. -J04406 When servicing the fuel system, do not smoke or allo w open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Softail and Dyna models: See the service manual and loosen the fuel tank. Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) 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) NOTES Immediately wipe up any brake fluid spills with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spilled DOT 4 brake fluid. 3. See the service manual and drain the brake fluid from the front brake reservoir and brake lines. Handlebar Removal – Dyna and Softail NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 1. Note the front brake line routing and the orientation of the banjo fittings. See the service manual and disconnect and remove the brake line. Save the banjo bolts, but discard the brake line gaskets. 2. Remove the plastic wiring retainer clips that secure the turn signal harnesses to the handlebar, if equipped. 3. Remove the front brake master cylinder and clutch lever assemblies from the handlebar.

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CUSTOM LED 2004-2006 YAMAHA ROAD STAR INTEGRATED TAIL KIT INSTALLATION INSTRUCTIONS

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Filed Under (Yamaha) by admin on 10-11-2010

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1 ) REMOVE THE SCREWS ON THE BACK SIDE OF THE TAIL LIGHT THAT HOLD THE CHROME TRIM TO THE TAIL LIGHT. 2 ) POSITION YOUR CUTTING WHEEL AS SHOWN IN THE PICTURE TO THE LEFT WHERE THE CLEAR PART OF THE LENS TURNS 90 DEGREES. THE CUTTING WHEEL SHALL REMAIN IN THE PLANE OF THE LENS. 3 ) PROCEED TO CUT INTO THE CLEAR LENS APPROXIMATELY HALF OF THE THICKNESS, ALL THE WAY AROUND THE PERIMETER OF THE LENS – BE SURE NOT TO CUT ALL THE WAY THROUGH BECAUSE IT WILL NOT GLUE BACK TOGETHER PROPERLY. SEE “TIPS FOR CUTTING YOUR LENS” BEFORE BEGINNING. TIPS FOR CUTTING YOUR LENS A) KEEP THE CUTTING WHEEL MOVING AND APPLY LIGHT PRESSURE. SITTING IN ONE SPOT WILL JUST MELT THE PLASTIC. WHEN YOU MAKE YOUR WAY AROUND THE ENTIRE PERIMETER, CLEAN ALL THE BURRED PLASTIC FROM AROUND THE EDGES AND FROM INSIDE THE GROOVE YOU’VE MADE. OPENING THE LENS 4 ) PLACE THE TIP OF A FLAT HEAD SCREWDRIVER IN THE GROOVE YOU HAVE CREATED. 5 ) GENTLY TWIST THE SCREWDRIVER TO CRACK THE GLUE ALONG THE GROOVE. NOTE: AS SOON AS YOU HEAR THE SOUND OF THE GLUE GIVING (A CRACK), MOVE THE SCREWDRIVER SLIGHTLY AND ADVANCE THE CRACK. SLOW AND STEADY IS THE NAME OF THE GAME HERE. IF YOU FIND A HARD SPOT, WEAKEN IT WITH THE CUTTING WHEEL AS NECESSARY. THE HARD PART IS OVER! YOU CAN RELAX NOW! 2 ©2005 Custom LED LLC. All Rights Reserved. 6 ) REMOVE THE SCREWS HOLDING THE STOCK LED BOARDS TO THE HOUSING (YOU WILL BE REUSING SOME OF THE SCREWS SO PUT THEM TO THE SIDE). 7 ) REMOVE THE STOCK LED ASSEMBLY FROM THE LENS HOUSING. YOU WILL NO LONGER NEED THE STOCK LED BOARD, DISPOSE OF IT AS YOU WISH. 8 ) GENTLY PRY OFF THE PLASTIC COVER TO EXPOSE THE DRIVER BOARD UNDERNEATH. 9 ) REMOVE THE SCREWS SUPPORTING THE DRIVER BOARD AND SNIP OFF THE THREE WIRES (BLUE, BLACK, YELLOW) AS SHOWN AS CLOSE TO THE CIRCUIT BOARD AS POSSIBLE! YOU WILL NEED TO CONNECT TO THESE WIRES LATER. 10 ) POP OUT THE LITTLE BLACK PLUG AS SHOWN IN THE PICTURE. YOU CAN POKE IT OUT FROM THE INSIDE OF THE HOUSING. WIRING UP YOUR CUSTOM LED BOARD PLACE YOUR CUSTOM LED INTEGRATED TAIL BOARD NEXT TO THE HOUSING AND MATCH THE WIRE COLORS AS FOLLOWS: TRY TO HANDLE THE CIRCUIT BOARD AS LITTLE AS POSSIBLE AS FINGERPRINTS AND DIRT WILL HINDER THE PERFORMANCE. • BLACK ON HARNESS TO 6″ BLACK ON CUSTOM LED BOARD • BLUE ON HARNESS TO 6″ BLUE ON CUSTOM LED BOARD • YELLOW ON HARNESS TO 6″ YELLOW ON CUSTOM LED BOARD USE THE THREE (3 OF 5) SUPPLIED ORANGE SPLICE CONNECTORS. PUSH THE TWO WIRES TO BE SPLICED TOGETHER INTO THE OPEN END. BE SURE TO PUSH THE WIRES ALL THE WAY IN (UNTIL YOU CAN SEE THEY HAVE REACHED THE OTHER SIDE). NOTE: YOU WILL NEED TO SEPARATE THE THREE WIRES FIRST BY CUTTING THE PLASTIC COLLAR THAT BINDS THEM. FOR THE WIRES TO FIT PROPERLY INTO THE CONNECTORS, YOU MUST ALSO REMOVE THE REMNANTS OF THE COLLAR FROM THE WIRES. NOTE: THE SPLICE IS MORE RELIABLE IF THE WIRE IS NOT STRIPPED. BE SURE TO SNIP OFF THE BARE ENDS OF THE WIRES ON THE CUSTOM LED TAIL TO ENSURE THAT THERE IS INSULATION WHERE THE SPLICE WILL OCCUR. THE SUPPLIED SPLICE CONNECTORS AUTOMATICALLY DISPLACE THE INSULATION AS NECESSARY. ONCE YOU DOUBLE CHECK YOUR COLOR MATCHING AND ARE ABSOLUTELY SURE THAT THE WIRES ARE FULLY INSERTED INTO THE SPLICE CONNECTORS DO THE FOLLOWING: 11 ) SQUEEZE THE SPLICE CONNECTORS FIRMLY WITH PLIERS. VISUALLY INSPECT YOUR CONNECTIONS TO SEE THAT THEY HAVE BEEN SPLICED PROPERLY INSIDE. 12 ) RUN THE GREEN AND BROWN WIRES THROUGH THE HOLE YOU OPENED UP IN STEP 9

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Yamaha 2005 R1 Bike Tech Sheet

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Filed Under (Yamaha) by admin on 18-01-2012

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Engine: Type: Liquid cooled, four stroke, transverse four cylinder, DOHC, 5 valves per cylinder. Displacement: 1000cc Year: 2005 Horsepower: 180hp Clutch: PM Exhaust: Vance & Hines Race Exhaust Mufflers: Vance & Hines Frame: Type: Stock Year: 2005 Swing Arm: Performance Machine Chromoly +4 Extended Shocks: Race Tech Modifications: Race Tech Tuned and Lowered. Forks: Stock lowered 2.5″ Rim: Performance Machine Contrast Cut Torque Size: 19″ X 3.0″ Finish: Contrast Cut Fender: None Tire: Dunlop Sportmax D208ZR 120/70ZR19 Brake: Dual Performance Machine 4 piston Radial Calipers Wheels Rear: Rim: Performance Machine Contrast Cut Torque Size: 18″ X 8.5″ Brake: Performance Machine 4 piston Radial Caliper Finish: Contrast Cut Tire: Dunlop Elite3 250/40/R18 Other Parts: Handlebars: Stock Foot Controls: Over Racing Seat: Stock Turn Signals F/R: Anything Extra? Mirrors: Performance Machine Torque chrome Mirrors 19″ FRONT WHEEL! Paint, Chrome, and other F/X’s: Colors: yellow/Black Type: Special Paint: AirTrix Industries The Painter: Chris Wood Powder Coating: A to Z Coatings

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1945-1957 AJS Pitmans Installaiton Manual

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Filed Under (AJS) by admin on 31-10-2010

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AN A.J.S. O.H.V. single is easy to handle, and even the absolute novice quickly acquires confidence in the saddle. Beware, however, that you do not indulge in big throttle openings until you have had ample road experience. Also do not forget to digest the Highway Code. FIG. 1. A FLEXIBLE AND FAST TOURER WITH CLEAN LINES AND MECHANICAL QUIETNESS – THE 1957 MODEL 18S The 500 c.c. A.J.S. model shown is similar to the 350 c.c. model 16MS. Both models have snappy push rod O.H.V. engines with light-alloy cylinder heads, “Monobloc” carburettors, hairpin valve-springs, and automatic-ignition control. Their specification includes: “Teledraulic” front forks, Girling rear-suspension units, a quickly detachable rear wheel, die-cast light-alloy hubs, a deep secondary-chain guard, a new A.M.C. four- speed gearbox, Lucas headlamp, twin pilot-lights, and other attractive features. * The A.J.S. engine and frame numbers required on Form R.F. 1/2 will be found on the near-side of the crankcase and the off-side of the saddle lug, or on the off-side of the front down-tube (later models). THE BOOK OF THE A.J.S. 1 Essential Preliminaries. Before you can legally ride on the road – (1) Insure against all third-party risks and obtain the vital “certificate of insurance.” With a new machine you cannot get this until the machine is licensed, and an insurance “cover note” must be obtained. If you have a valuable machine, you are advised to take out full comprehensive insurance. (2) Obtain the registration licence and registration book (Form R.F.I/2)* or renew the licence (Form R.F. I/A). (3) Obtain a three-monthly “provisional” or an annual driving licence (Form D.L.I).* (4) Fit a reliable speedometer if one is not fitted (not essential if machine registered prior to 1st Oct., 1937). (5) If you carry a pillion-passenger, see that he or she sits astride a proper pillion seat securely fixed to the machine (all “springers” have dualseats), and that the passenger holds a current annual or substantive driving licence for Group G if you are a “learner.” (6) If you are ineligible for an annual or substantive driving licence, attach “L” plates to the front and back of the machine. (7) If not already provided, fit a red reflector (1½ in. minimum diameter) vertically at the rear of the motor-cycle and, on a sidecar outfit, an additional red reflector and rear lamp at the rear of the sidecar and at the same height as those on the motor-cycle. (8) Use an ignition-suppression type sparking plug or terminal cover if the machine was registered for the first time after 1. st July, 1953. All the official forms referred to above may be obtained from any money-order post office. See also footnote **, with reference to Forms R.F, 1/A or R.F. 112. You are not eligible for a substantive driving licence for Group G unless you are 16 and have complied with one of these conditions- (a) You have held a licence (other than a provisional or Visitor’s licence authorizing the driving of vehicles of the class or description applied for within a period of ten years ending on the date of coming into force of the licence applied for. (b) You have passed the prescribed driving test (this includes a test passed while serving in H.M. Forces) during the said period of ten years

HARLEY DAVIDSON SOFTAIL BRAIDED REAR BRAKE LINE KIT INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 04-02-2011

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INSTALLATION Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00240a) Direct contact of D.O.T. 5 brake fluid with eyes can cause eye irritation, swelling, and redness. Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention. Swallowing large amounts of D.O.T. 5 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN. (00144a) 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) Drain Brake Fluid 1. Pop off bleeder nipple cap on the rear brake caliper. 2. Install one end of a length of plastic tubing over the caliper bleeder valve. Place the free end of the tubing into a suitable container. 3. Open the bleeder valve about 1/2-turn and pump the brake pedal to drain the brake fluid out of the rear brake system. Do not reuse brake fluid. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) Remove Existing Rear Brake Line 1. Disconnect wiring harness connectors from brake light switch spade terminals. Avoid leakage. Be sure gaskets, banjo bolt(s) and brake line are clean and undamaged before assembly. (00323a) 2. Disconnect existing brake line from rear brake caliper and rear brake master cylinder assembly. Save banjo bolts, but discard brake line gaskets. NOTE This kit contains all gaskets needed for replacement. 3. Carefully make note of rear brake line routing and orientation of banjo fittings, then remove existing brake line. Save hex head screw holding brake light switch manifold to tab on frame, but discard brake line and attaching parts. 4. Unthread brake light switch from brake line. Save switch for later use.

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