05. (fig. 1) Guide the slave cylinder through
the front fork from the top downwards,
routing the hydraulic hose in the same
manner as the OEM clutch cable was
routed. Insert the cable end of the slave
cylinder into the primary cover and tigh-
ten the threaded end of the slave cylin-
der. Hold the slave cylinder in the
installed position and rotate the ramp
assembly clockwise until any play is
eliminated. Now the ball on cable end
of the slave cylinder should be at most
+/- 0.1" from the cable coupling. If this
is not the case, carefully readjust the
clutch ramp setting.
06. Snap the cable ball of the slave cylinder into the cable coupling.
07. Unscrew the forward end cap of the slave cylinder and remove the white spacer.
Screw the end cap back on again. Tighten securely. (fig. 2)
08. Actuate the master cylinder lever twice. The resulting movement of the slave cylinder
actuates the ramp assembly and disconnects the clutch.
09. Reinstall the clutch cover and tighten it down, making sure that the sealing O-ring is
in position.
10. Slide the protective hose over the bush inserted in the hose connector.
11. Secure the hydraulic hose to frame with the original clutch cable clamps. Also secure
it at other suitable points with additional cable clamps as necessary to prevent contact
with moving or hot components.
12. lf possible accommodate excess length of the hose by making a loop in it at a conve-
nient place. This dispenses with the need to open the system to shorten the hose.
Then proceed with the attachment of the master cylinder to the handlebar. If the hose
is not the right length, proceed as follows:
13. Loosen the hose connector on the master cylinder with the 8 mm wrench. Remove the
master cylinder from the handlebars and place the opened master cylinder on the
workbench so that the opening is facing upwards and no fluid can leak out.
14. Carefully and slowly move the open hose end as described below; this will ensure that no
fluid can escape. The loss of fluid impairs the operation of the system! Push the
retaining nut backwards to the section of the hose that will not be trimmed. Shorten the
hose to the correct length. The end of the hose should easily reach the switch housing
with the handlebars turned to the fork stop in both directions. Caution! Once hoses
fig. 2
➧
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