1.0 PARTS LIST
SLAVE CYLINDERNED’s (Dave) Hydraulic Clutch Kit
- Hose Fitting Thread Pitch: 10 X 1.25mm
- Piston Travel (With Magura 9.5mm M/C): 0.080”
- Seal: 7/8” Wheel Cylinder Cup Seal
NAPA - PT# 3023
LINK:
www.napaonline.com/en/p/UBP20412MASTER CYLINDERMagura: OEM Replacement Master Cylinder 9.5mm – PT# 2000302
- Hose fitting Thread Pitch: 10 x 1.0mm
- Magura Mirror Mount Bracket - PT# 2700177
*BOTH AVAILABLE ON EBAY
www.amazon.com/dp/B000GV2920?tag=viglink20248-20FLUID- Recommended: DOT 5
SEALS- 10mm Parker Stat-o-Seals
*Available on Ebay
HOSEThis is using all Russell Performance Parts.
*This is only made as a quick reference guide for the Hose
*Applications vary based on Bike Model, Handle bars, Gauges, Carbs etc etc
www.russellperformance.comRUSSELL Factory Assembled Universal Brake Hoses
*Available in multiple finishes
- Available in a variety of lengths (Check on your bike before ordering)
LINK:
www.russellperformance.com/powersports/mc/brake-clutch-hose-kits/universal.shtmlFITTINGS*Available in multiple finishes
This is using all Russell Performance Parts.
*This is only made as a quick reference guide for the fittings
*Applications vary based on Bike Model, Handle bars, Gauges, Carbs etc etc
www.russellperformance.comSLAVE CYLINDER Fittings- Banjo Bolt 10mm x 1.25: PT# R40516C (Chrome Finish)
- Banjo 45°: PT# R4055C (Chrome Finish)
OR- Banjo 35°: PT# R4050C (Chrome Finish)
LINK:
www.russellperformance.com/powersports/mc/adapter-fittings/index.shtml
MASTER CYLINDER Fittings*M/C to HOSE Thread Pitch 10mm x 1.0
- There have been TWO suggested methods
(1) DIRECT HOSE TO M/C CONNECTION
- Male Flare Union: PT# R41431
(2) BANJO APPLICATION
- Banjo Bolt 10mm x 1.0: PT# R40506 (Chrome Finish)
- Banjo 45°: PT# R4055C (Chrome Finish)
OR- Banjo 35°: PT# R4050C (Chrome Finish)
LINK:
www.russellperformance.com/powersports/mc/adapter-fittings/index.shtml 2.0 INSTALLATION2.1 SLAVE CYLINDERThis is NOT meant as an “OFFICIAL” instruction but rather only a collaboration of tips/tricks from the various comments/members on the KTC forum.• Piston should be greased upon assembly as there is no fluid contact to lubricate this in service.
- Recommend very thick Silicone grease (compatible with rubber).
Ex. Dow Corning 111. Labeled "Valve lubricant and Sealant"
(for disk brake slider/pad tip lubrication). It does not wash off like other caliper greases.
• Ensure that Seal AND Piston are both orientated properly.
2.2 CLEARANCE / INTERFERANCESLAVE TO ENGINE CASESWhen installing the slave, be sure that it seats properly. Some applications may have slight interference. It can be resolved quickly with a dermal. Luckily, it's between the mounting bolts so it's easy to feel the rocking (the shinny spot on the top where there is a ledge from machining).
PERFECT FIT
PUSH RODIF you are using a ball bearing pusher you may be required to trim down your push rod accordingly to make up for the added length from the ball bearing pusher.
*BE CAUTIOUS AND ENSURE THAT ALL MEASUREMENTS ARE CORRECT BEFORE TRIMMING
ENGINE COVERBased on your selected fitting application modification may be required to your LH Engine Sprocket Cover to accommodate the hydraulic clutch hose.
*BE CAUTIOUS AND ENSURE THAT ALL MEASUREMENTS ARE CORRECT BEFORE CUTTING
2.3 MASTER CYLINDER / MIRROR MOUNT
2.4 FITTINGS• Applications vary based on Bike Model, Handle bars, Gauges, Carbs etc.
• Refer to “1.0 PARTS LIST” for all LINKS to RUSSELL PERFORMANCE PRODUCTS
SLAVE CYLINDER RECOMMENDATIONS- Banjo Bolt 10mm x 1.25: PT# R40516C (Chrome Finish)
- Banjo 45°: PT# R4055C (Chrome Finish)
OR- Banjo 35°: PT# R4050C (Chrome Finish)
MASTER CYLINDER RECOMMENDATIONS*M/C to HOSE Thread Pitch 10mm x 1.0
(1) DIRECT - HOSE TO M/C CONNECTION
- Male Flare Union: PT# R41431
-
(2) BANJO APPLICATION
• Available Russell Banjo bolt is too long. If it is cut the chrome plating may have a burr and give troubles. *USE AT YOUR OWN RISK OR SOURCE A SHORTER BOLT
- Banjo Bolt 10mm x 1.0: PT# R40506 (Chrome Finish)
- Banjo 45°: PT# R4055C (Chrome Finish)
OR- Banjo 35°: PT# R4050C (Chrome Finish)
2.5 HOSERUSSELL Factory Assembled Universal Brake Hoses*Available in multiple Lengths & Finishes
• The Russell hose length is quoted tip to tip and there is no compensation for the additional length of the fittings.
DETERMINING HOSE LENGTH• Install the Master and Slave Cylinders with their respective fittings.
• Using a piece of 3/8” ID fuel hose; route and trim as needed with the hose plugged onto the threaded fittings.
• Remove the fuel hose and measure its final length.
• Use this value to determine the length of hose to order from Russell.
2.6 FINAL ASSEMBLY AND BLEEDING
• Assemble and install your Master Cylinder and fittings / hose.
• Leave the Slave Cylinder UNBOLTED from the Engine Cases.
• DO NOT bleed through the Slave Cylinder’s bleed screw. Rather use it to fill the system via a syringe.
• Insure the line into the Master is LOWER than the ball end of the lever.
• Make sure there are no high spots in the line
• Hold the Slave Cylinder in one hand with a finger over the piston.
• Pump the Master Cylinder so the piston comes out of the Slave Cylinder 0.125"
• Slowly push the piston back into the bore.
*DO NOT push it all the way in; Seal damage CAN occur from being pushed past the ports!
• The DOT 5 fluid likes to froth.
• GO SLOWLY!
• Repeat until all the air is out.
ENJOY!!
