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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HONDA GL 18001-RP Illuminator Replacement Lamp Set Installation Instructions

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Filed Under (Honda) by admin on 23-12-2010

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1. Remove the plastic caps covering the brake and clutch master cylinder clamp bolts, remove the clamp bolts and clamps. Pull the master cylinders away from the handlebars and let them rest on the fairing storage compartment covers. 2. Using a heat gun or a hair dryer warm up the old lamps one at a time until they are hot to the touch then carefully peel them away from the switch housings. 3. Remove any remaining adhesive from the old lamps left on the housings using rubbing alcohol. Locate the wire harness to the lamp connectors covered with heat shrink tubing. Using a sharp knife carefully cut the heat shrink tubing open lengthwise. Carefully taking caution to not cut the wires, peel the heat shrink tubing open, then away and off the connection. Unplug the lamps from the harness. Replace any of the gold pin connectors on the harness if needed with the new ones supplied. 4. Slide the heat shrink tubing over the gold pins and wire harness ends. Carefully plug the gold pins from the harness onto the lamp connectors (NOTE: the metal connectors on the lamps can break if bent from side to side).Turn on the ignition and verify that all three lamps are working. Slide the heat shrink tubing over the connections and shrink using a heat gun, hair dryer or lighter being careful not to melt the lamp ends. 5. Using your heat gun or hair dryer warm one of the switch housings and the matching lamp so that they are hot to the touch (about 140 degrees). Peel the backing from the lamp, carefully place in position, press firmly onto housing, wrap the tail of the lamp with the wires around the housing and then rub over the entire lamp firmly several times to ensure good adhesion. 6. Reassemble the master cylinders and clamps onto the handlebars being careful not to pinch the wires or lamps.

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