Automotive Manual PDF

Thank you for the purchase of this rear disc brake kit for the CRF/XR50! Everything is included in this kit to add a rear disc brake to your BBR Perimeter Aluminum Frame kit based motorcycle. If you are adapting this kit to the OEM Honda frame or another aftermarket frame kit, you will need our adapter kit PN 550-HXR-5050. Because installation of this kit is beyond the control of BBR Motorsports, Inc, we cannot accept responsibilty for misuse or improper installation. This kit is intended only for use on off-road motorcycles. These instructions are intended only as a supliment to the proper Honda service manual. If the installation of this product is beyond your technical abilities please refer to qualified service personel.
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Step 1:
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.
To ensure no paint damage from a brake fluid spill, completely cover the bike. This process can be messy, and brake fluid WILL drip!
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This system is intended for “off road use only”
1. Please carefully inspect the entire braking system thoroughly, and replace any marginal items. Installation of braided steel, high performance brake lines is highly recommended, though not mandatory.
2. Please carefully inspect the entire power steering system thoroughly, and replace any marginal items. This system will not function properly unless the power steering system is 100%
3. Disconnect the battery.
4. Disconnect the brake pedal rod connection at the brake pedal.
5. Disconnect the master cylinder from its mounting, and secure it approximately 6 inches forward (if brake line integrity / routing permits – otherwise remove the master cylinder).
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Proper operation of your brakes is essential for your safety and the safety of others. Any brake service should be performed ONLY by persons experienced in the installation and proper operation of brake systems. It is the responsibility of the person installing the component or kit for the particular application. After installation and before operating your vehicle, be sure to test the function of the brakes under controlled conditions.
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Some different models or years of vehicle may use different sized fasteners. Every effort has been taken to correctly identify the proper sized tool for each job. Occasionally, the manufacturer may use an alternate fastener. Check that each tool correctly fits the fastener before loosening or tightening it. The following tools and equipment will be needed:
14mm wrench (in some cases, 9/16” may be required)
11mm box wrench (in addition, an 11mm flare wrench is also recommended)
10mm wrench or socket
10mm Allen (hex) wrench
8mm Allen (hex) wrench
Vise-grip or pliers
Needle-nose pliers or small flat-blade screwdriver
Torque wrenches capable of 10-85 lb-ft settings
Small drip tray or several rags
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Clutch is a single, dry disc type using a hydraulically operated master cylinder and clutch housing mounted slave cylinder. On Land Cruiser, slave cylinder is adjustable. On all others, slave cylinder is nonadjustable. Clearance is automatically compensated by internal design of cylinder.

PEDAL HEIGHT & FREE PLAY
Rotate pedal stop bolt at top of pedal assembly to adjust pedal height. To adjust free play, loosen lock nut on master cylinder push rod and turn push rod in or out to specified free play. See CLUTCH PEDAL SPECIFICATIONS TABLE. Tighten lock nut.
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The System Priming Procedure is only necessary before the first time use of the BFX or when changing brake fluid types. Between normal operation cycles, this procedure will not be necessary.
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When ignition is turned on, control module activates warning indicators on instrument panel and performs an initial diagnostic test which ensures there are no internal faults in control module. At same time, main relay portion of combination relay is activated so hydraulic modulator valves are supplied with power. See Fig. 1. Control module then checks operation of valves by activating them in sequence.
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Installation Instructions Front
1. Raise vehicle and place jack stands under frame approximately 3” behind front spring shackles. Remove front wheels and shocks.
2. Remove one rivet from the outside of the frame at the engine cross member closest to the OE hose to steel line connection. Attach the 90 degree brake line extension brackets using the 3/8” x ” bolts, nuts, and lock washers.
3. Disconnect front brake line at frame and reroute through extension brackets and secure. CAUTION: Careful attention must be exercised in rerouting. Do not kink, pinch or stretch lines! When both sides have been completed, bleed the brakes. Refill the master cylinder with Dot ap- proved fluid.
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