1998-2001 HONDA VFR 800 Complete Brake Line Kit INSTALLATION

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Filed Under (Honda) by admin on 14-12-2011

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Identify the key components that complete our brake line kit: You should have nine (9) hoses, one (1) double banjo bolt, fourteen (14) single banjo bolts, (1) single bleeder bolt three (3) drawings, and a picture CD. There are also a total of forty (40) washers and two (2) “olive” conic inversors. Thirty six washers will be used, and two olives. The rest are spares.Step 2: Familiarize yourself with the brake lines, which are labeled for application. Lettered brake hoses A, B, C, D, E, F, G are installed on the front of the motorcycle, while brake hoses (H and I) are installed on the rear. Each label will reference a different drawing, which will show you the location of the key brake system
components.Step 3: To ensure no paint damage from a brake fluid spill, completely cover the bike. This process can be messy, and brake fluid WILL drip! Step 3: Dry out (bleed) your OEM hoses, and take note of how the stock system is installed. You may want to take a couple pictures, in case you need to re-install. Step 4:Remove the stock hoses on the front of the motorcycle, and replace with Galfer hoses labeled A,B,C,D,E,F,G. Locate lines A. this hose will run from the master cylinder down to the right caliper and across the fender through the C-CLIP down to the left caliper. Line D. will run from the (DELAY VALVE) up through the C-CLIP to the right side upper frame female fitting will thread into the male with a (OLIVE) this O.E.M tubing travels to the proportion valve. Line F will run from the left caliper up through the C-CLIP to the left upper frame female fitting and thread to the male with a (OLIVE) this tubing travels to the rear master cylinder. Locate and install line E; this hose will run from the lower delay valve down to the right caliper. locate and install line C& G; line G will travel from the bottom (left) mounting point on the left caliper, to the upper inner mounting point of the left caliper this line joins line C with a double banjo bolt. line C will travel from the inner left caliper through the C-CLIP across the front fender to the inner mounting point of the delay valve

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.

Toyota Camry L4 – 2.4L 2004 Brakes and Traction Control Disc Brake System Service and Repair

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Filed Under (Toyota Manuals) by admin on 24-05-2011

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REMOVE FRONT DISC BRAKE CYLINDER SLIDE BUSH 10. Remove the cylinder slide bush from the cylinder slide pin.
a. REMOVE FRONT DISC BRAKE BUSH DUST BOOT 11. Remove the 2 bush dust boots from the disc brake cylinder mounting. a. REMOVE FRONT DISC BRAKE CYLINDER MOUNTING LH 12. Remove the 2 bolts and disc brake cylinder mounting LH. a. REMOVE CYLINDER BOOT 13. Using a screwdriver, remove the set ring and cylinder boot.
a. REMOVE FRONT DISC BRAKE PISTON 14. Place a piece of cloth or similar, between the piston and the disc brake cylinder. a. Use compressed air to remove the piston from the disc brake cylinder. CAUTION: Do not place
your fingers in front of the piston when using compressed air. NOTICE: Do not spatter the brake fluid

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HARLEY DAVIDSON CHROME 1.00 INCH (25.4 MM) DIAMETER HANDLEBAR KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-04-2011

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INSTALLATION Preparation To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b) 1. Refer to the Service Manual and follow the instructions given to remove the main fuse. 2. For FLTR models only: Refer to UPPER FAIRING AND WINDSHIELD: FLTR: OUTER FAIRING: REMOVAL in the Service Manual, and follow the instructions to remove the outer fairing. See INSTRUMENT NACELLE: FLTR: REMOVAL in the Service Manual, and remove the instrument nacelle and bezel. For ALL models: 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)

HARLEY DAVIDSON DYNA GLIDE BRAIDED REAR BRAKE LINE KITS INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 28-04-2011

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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 rear brake caliper. 2. Install one end of a length of plastic tubing over caliper bleeder valve. Place free end of the tubing in 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. See Figure 1. Disconnect wiring harness connectors from brake light switch spade terminals.

Yamaha XVS650 and 1100 Drag Star/V-Star Service and Repair Manual

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Filed Under (Yamaha) by admin on 27-04-2011

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Fortunately, Haynes cruises to the rescue with the introduction of its new Service and Repair Manual for all Yamaha XVS650 and 1100 models – XVS650 (‘97-’05), XVS650A Classic (‘98-’05), XVS1100 (‘99–’05) and XVS1100A Classic (‘00–’05). Hailed as “… essential reading for any biker tackling his own servicing…” by Motor Cycle News, Haynes manuals have an enviable reputation. The new manual provides fully illustrated, step-by-step instructions for DIY servicing, overhaul and repairs of the engine and transmission, fuel and ignition systems, suspension and steering, the braking system and the electrical system. Each task is given a spanner rating for complexity and experience required. Checking and adjusting the valve clearances is rated as three spanners out of five. There are full-colour sections on the history of the models, on daily preride hecks and those all-important wiring diagrams, plus tools required and Haynes Hints. For instance, when changing the brake fluid how to tell when all the old fluid has been displaced The section guiding readers

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HARLEY DAVIDSON TALL HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 16-04-2011

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INSTALLATION Preparation Models WITH maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse. Models WITHOUT maxi-fuse: To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware. 2. Remove the outer fairing. See UPPER FAIRING/WINDSHIELD (FLHX, FLHT/C/U), OUTER FAIRING/WINDSHIELD, REMOVAL in the Service Manual. Remove the fairing cap. See UPPER FAIRING/WINDSHIELD; FAIRING CAP: REMOVAL in the Service Manual. 3. Bleed the brake fluid from the front brakes per the instructions in the Service Manual. Original Handlebar Removal NOTE Cover the front fender and the front of the fuel tank with clean shop towels to prevent scratching. Damage to the finish could result. 1. Models WITH radio: Remove the radio. See RADIO: REMOVAL in the Service Manual. Models WITHOUT radio: Remove the storage box. a. The four socket head screws fastening the storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws. b. Pull the storage box forward to remove it from the opening in the inner fairing. Remove brake line components carefully. Damage to seating surfaces can cause leakage. (00320a) 2. Disconnect the front brake lines from the vehicle. See FRONT BRAKE MASTER CYLINDER, FRONT BRAKE LINE, REMOVAL, FLHX, FLHT/C/U in the Service Manual

HARLEY DAVIDSON NARROW BEACH HANDLEBAR KIT INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 14-04-2011

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INSTALLATION Preparation 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. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the battery cables, negative cable first. Retain all seat mounting hardware. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00330a) 2. Loosen the fuel tank. Refer to FUEL TANK REMOVAL in the appropriate section (Carbureted or EFI Engine) of the Service Manual. 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

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 REPLACEMENT BRAKE PAD/PASTE KIT

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Filed Under (Harley Davidson) by admin on 26-03-2011

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REMOVAL 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. Remove the brake caliper and pad following the instructions in the service manual. Discard pin and clip. For Kit 41852-08A: Discard brake pads. INSTALLATION Always replace brake pads in complete sets for correct and safe brake operation. Improper brake operation could result in death or serious injury. (00111a) Prepare the Replacement Brake Pads 1. Remove paper backing from the mask. 2. See Figure 2. Carefully align and apply the mask (1) to the non-friction side of the brake pad (Figure 1, Item 2). NOTES Gloves are recommended when applying the brake pad paste to keep hands clean. 3. See Figure 4. Apply paste (6) in the mask holes until the holes are filled with paste. NOTE To prevent brake paste from transferring to other surfaces, do not apply paste thicker than specified. 4. See Figure 3. Wipe away excess paste with scraper (1) until the paste is the same thickness as the mask (2)

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