Brake Side
Removal
Remove Stock
Bolts That Mount Brake Assembly to Frame- This is easy enough but
pay attention to the Brake Pedal return spring and bushing. It is
under pressure (not too much) and you will have to exert the same
pressure to put it back.
Remove Stock
Brake pivot linkage- This is a little tricky after you remove the
retaining clip. The brake actuator rod has a U shaped stamping
that is held in place by a nut and a rolled pin. The rolled pin is
really really small and difficult to drive out. I used a tiny
allen wrench. The U bracket will then screw off (with difficulty)
using a crescent wrench to grip it or a screwdriver through the
holes. If you aren’t worried about saving it vice grips would work
better. You can use the locking nut to stabilize the rod while you
do this.
Installation
Install
New Plate
This is easy
but start all the bolts before tightening them.
The directions supplied reversed the bolts so you have to use the
long one with the bushing on the bottom and the short one on the
top.
Install the
new brake pivot linkage (brake rod extension) to the existing
brake rod. Adjust it to where you think its close. You’ll have to
adjust it again after the pedal assembly is put back.
Install
brake assembly to new plate
This gets a
little tricky. With the new bolts supplied with the kit, start the
long bottom bolt through the footrest base, into the new bracket,
through the brake pedal return spring and bushing (being careful
not to lose the o-rings on the bushing). This is where the tension
on the return spring comes in. If you rotate the whole assembly
toward the front of the bike this is much easier. Put on the
washer and the lock nut but don’t tighten too much. Then rotate
the assembly back and install the top (short) bolt. Be sure you
put the washer next to the lock nut or the bushing will bind up.
Be sure the brake pedal return spring stays in the hole provided
in the new plate. It will be very close and probably touch the
footrest base.
Attach
Brake Rod Extension to brake pedal
They left
this part out! One side of the extension is threaded to take the
bolt supplied. If you tighten it enough to hold the bolt in place
it binds the brake pedal and it won’t return fully. I threaded a
longer bolt completely through without tightening it too much and
used double nuts to lock it.
Shifter
Side
Remove
Shifter Rod
This is a
little tricky also-the threads are opposite on each end. Loosen
the nuts and it will unscrew from both ends at once.
Remove
shifter assembly and footpeg
Pretty
straight forward.
Mount
new plate with stock bolts
Ditto
Install new
shifter rod -to transmission linkage first. On my kit the nuts
would not thread on the new shifter rod so there are no locking
nuts. (Remember the left hand threads!) Mount the shifter to the
other end of the rod. Be sure you do enough turns in each end for
it to be secure. The more turns you use, the lower your shifter
peg will be in relation to the pedal.
Mount
footrest using new bolts supplied.
Go back and
check for tightness and function.
YOU ARE
DONE!
I hope this
helps a little. It took me about an hour with the mistakes so it
really isn’t too bad. It is probably a good idea to do this out of
earshot of young children and those sensitive to profanity. If you
don’t scrape your knuckles at least once you’re not trying hard
enough. Good Luck!
Editors Note:
Dennis Kirk Catalog part # 49-9282, price $110 Thanks Dave (BLUEBIKE)
