06. Remove the clutch cable along with the
mechanical clutch lever.
07. Take the hydraulic system out of the
packaging.
08. Take the screw plug with the 5/16“-24
thread out of the packaging and screw
it into the clutch cable mounting hole on
the transmission end cover and tighten
it with the 14 mm wrench (torque fitting
to 53 inch pounds).
09. Loosen the hose connector on the
master cylinder with the 8 mm wrench.
Place the opened master cylinder on the
workbench so that the opening is facing
upwards and no fluid can leak out.
10. 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! Cut off 1 inch
of the end of the hose using a hose cutter or a sharp knife but not with scissors or a
side cutting pliers. Then remove the retaining nut from the hose.
11. Feed the end of the hose from inside through the screw plug on the transmission end
cover until the slave cylinder fits into the bore in the transmission end cover. (fig. 2)
Make sure that the side-locking pin is engaged in the groove in the transmission end
cover. When inserting the slave cylinder, do not press on the piston as otherwise fluid
will drip onto the end of the hose! When installation is complete, the hose should be
gently arched. (fig. 3) Do not let the hose kink.
12. Re-insert the retaining ring with the retaining ring pliers. Make sure that it securely
snaps into place!
13. Install the two protective tubes over the hose. Use a lubricant, such as silicone spray.
14. Install the transmission end cover with the installed slave cylinder. Replace the end cover
gasket if it appears damaged. Carefully route the hose the same way as the original
clutch cable was routed, to the handle bar. Do not forget to feed it through the forks!
15. Shorten the hose to the correct length. The end of the hose should easily reach the
switch housing. Caution! Once hoses have been cut too short, it is not possible
to subsequently attach an extension! When shortening a hose cutter or a
sharp knife may be used but not scissors or side cutters. You want a nice square
end on the hose. It may also be necessary to shorten the outer protective hose.
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Continuation on next page
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